Fiber-bound engineered materials formed utilizing carrier screens

ABSTRACT

A method of forming a fiber-bound engineered material utilizing carrier screens is provided that imparts an intended characteristic at an intended relative location. Also provided are articles formed of fiber-bound engineered materials manufactured utilizing carrier screens. A fiber layer is placed adjacent at least one carrier screen and entangled with additional fibers in a manner to create a non-uniform engineered material. The lack of uniformity of a fiber-bound engineered material may be accomplished through manipulation of the fibers and/or through fiber binding a scrim. The fiber layer binds with additional fibers through entanglement such that a mechanical connection between the entangled fibers is provided. This entanglement allows the fibers to bind without supplemental adhesives, interlacing, or connections.

FIELD OF THE INVENTION

Aspects hereof relate to engineered textiles having fiber binding andmethods of forming the same. Aspects further relate to engineeredtextiles formed utilizing carrier screens.

BACKGROUND OF THE INVENTION

Stock materials, such as rolled goods, traditionally have a uniformfunctional characteristic throughout the material. To form engineeredarticles from the stock materials, the stock materials may be cut intoindividual pieces and layered and/or combined to build the engineeredarticle. The layering and combining of discrete pieces can increasecosts, increase bulk, increase waste, and limit design options for theresultant engineered article.

SUMMARY OF THE INVENTION

Aspects hereof provide a fiber-bound engineered material, and methods ofmaking the same, that provides an intended characteristic at an intendedrelative location. A fiber layer is entangled with additional fibers ina manner that creates a non-uniform engineered material. That is, afiber layer is entangled with additional fibers in a manner that createsan engineered material having at least one non-uniform functionalcharacteristic. Lack of uniformity in a fiber-bound engineered materialmay be accomplished through manipulation of the fibers forming the fiberlayer, manipulation of additional fibers, and/or through fiber-binding ascrim. The fiber layer binds with additional fibers through entanglementsuch that a mechanical connection between the entangled fibers iscreated. This entanglement allows the fibers to bind withoutsupplemental adhesives, interlacing, or connections. Variations in thefibers and/or inclusion of scrim materials prior to entanglement allowsfor an intended characteristic (e.g., a functional characteristic) at anintended relative location (e.g., a position determined by an article tobe formed therefrom).

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE DRAWING

Illustrative aspects hereof are described in detail herein withreference to the attached drawing figures, which hereby are incorporatedby reference and wherein:

FIG. 1 is a schematic diagram depicting an exemplary article offootwear, in accordance with aspects hereof;

FIG. 2 depicts a plan view of the exemplary article of footwear of FIG.1, in accordance with aspects hereof;

FIG. 3A depicts an exemplary fiber layer, in accordance with aspectshereof;

FIG. 3B depicts a cross-section of the exemplary fiber layer of FIG. 3A,in accordance with aspects hereof;

FIG. 3C depicts an exemplary fiber layer formed from continuous fibers,in accordance with aspects hereof;

FIG. 3D depicts an exemplary continuous fiber layer roll having aplurality of article profiles placed thereon, in accordance with aspectshereof;

FIG. 4A depicts the exemplary fiber layer of FIG. 3A having a scrimplaced thereon, in accordance with aspects hereof;

FIG. 4B depicts a cross-section of the exemplary fiber layer/scrimassembly of FIG. 4A, in accordance with aspects hereof;

FIG. 5A depicts the exemplary fiber layer/scrim assembly of FIG. 4Ahaving an additional fiber layer placed thereon, in accordance withaspects hereof;

FIG. 5B depicts a cross-section of the exemplary fiber layer/scrim/fiberlayer assembly of FIG. 5A, in accordance with aspects hereof;

FIG. 6A depicts the exemplary fiber layer/scrim/fiber layer assembly ofFIG. 5A subsequent to entanglement, in accordance with aspects hereof;

FIG. 6B depicts a cross-section of the exemplary entangled assembly ofFIG. 6A, in accordance with aspects hereof;

FIG. 7A depicts an exemplary multiple fiber layer arrangement, inaccordance with aspects hereof;

FIG. 7B depicts an article formed from the exemplary multiple fiberlayer arrangement of FIG. 7A, in accordance with aspects hereof;

FIG. 8A depicts a second exemplary multiple fiber layer arrangement, inaccordance with aspects hereof;

FIG. 8B depicts an article formed from the second exemplary multiplefiber layer arrangement of FIG. 8A, in accordance with aspects hereof;

FIG. 8C depicts a cross-section of the second exemplary multiple fiberlayer arrangement of FIG. 8A, in accordance with aspects hereof;

FIG. 9A depicts a third exemplary multiple fiber layer arrangement, inaccordance with aspects hereof;

FIG. 9B depicts an article formed from the third exemplary multiplefiber layer arrangement of FIG. 9A, in accordance with aspects hereof;

FIG. 10A depicts a fourth exemplary multiple fiber layer arrangement, inaccordance with aspects hereof;

FIG. 10B depicts a lateral perspective view of an article formed fromthe fourth exemplary multiple fiber layer arrangement of FIG. 10A, inaccordance with aspects hereof;

FIG. 10C depicts a medial perspective view of an article formed from thefourth exemplary multiple fiber layer arrangement of FIG. 10A, inaccordance with aspects hereof;

FIG. 11A depicts an exemplary scrim assembly, in accordance with aspectshereof;

FIG. 11B depicts a cross-section of the exemplary scrim assembly of FIG.11A, in accordance with aspects hereof;

FIG. 12A depicts a second exemplary scrim assembly, in accordance withaspects hereof;

FIG. 12B depicts a cross-section of the second exemplary scrim assemblyof FIG. 12A, in accordance with aspects hereof;

FIG. 13A depicts a third exemplary scrim assembly, in accordance withaspects hereof;

FIG. 13B depicts a cross-section of the third exemplary scrim assemblyof FIG. 13A, in accordance with aspects hereof;

FIG. 14A depicts a fourth exemplary scrim assembly, in accordance withaspects hereof;

FIG. 14B depicts a cross-section of the fourth exemplary scrim assemblyof FIG. 14A, in accordance with aspects hereof;

FIG. 15 depicts an exemplary engineering-element scrim, in accordancewith aspects hereof;

FIG. 16 depicts a second exemplary engineering-element scrim, inaccordance with aspects hereof;

FIG. 17 depicts a third exemplary engineering-element scrim, inaccordance with aspects hereof;

FIG. 18A depicts an exemplary scrim configuration, in accordance withaspects hereof;

FIG. 18B depicts a medial perspective view of an article formed from theexemplary scrim configuration of FIG. 18A, in accordance with aspectshereof;

FIG. 18C depicts a plan view of the article illustrated in FIG. 18B, inaccordance with aspects hereof;

FIG. 19A depicts an exemplary scrim collection, in accordance withaspects hereof;

FIG. 19B depicts an article formed from the exemplary scrim collectionof FIG. 19A, in accordance with aspects hereof;

FIG. 20A depicts an exemplary perimeter scrim, in accordance withaspects hereof;

FIG. 20B depicts an article formed from the exemplary perimeter scrim ofFIG. 20A, in accordance with aspects hereof;

FIG. 21A depicts an exemplary heel-end scrim, in accordance with aspectshereof;

FIG. 21B depicts an article formed from the exemplary heel-end scrim ofFIG. 21A, in accordance with aspects hereof;

FIG. 22A depicts an assembly having a plurality of exemplary scrimelements, in accordance with aspects hereof;

FIG. 22B depicts a cross-section of the assembly of FIG. 22A, eachexemplary scrim element being positioned between first and second fiberlayers, in accordance with aspects hereof;

FIG. 22C depicts the assembly of FIG. 22B subsequent to entanglement ofthe first and second fiber layers, in accordance with aspects hereof;

FIG. 22D depicts a plan view of certain exemplary entangled elementssubsequent to a trimming operation, in accordance with aspects hereof;

FIG. 22E depicts a cross-section of the exemplary assembly of FIG. 22D,in accordance with aspects hereof;

FIG. 23A depicts a schematic diagram of a zipper, in accordance withaspects hereof;

FIG. 23B depicts a cross-section of the zipper of FIG. 23A positionedbetween first and second fiber layers, in accordance with aspectshereof;

FIG. 23C depicts the exemplary assembly of FIG. 23B subsequent toinitial entanglement of the first and second fiber layers, in accordancewith aspects hereof;

FIG. 23D depicts the exemplary assembly of FIG. 23C subsequent to fullentanglement of the first and second fiber layers and performance of atrimming operation, in accordance with aspects hereof;

FIG. 24A depicts hook-and-loop elements positioned between respectivefirst and second fiber layers, in accordance with aspects hereof;

FIG. 24B depicts the exemplary assemblies of FIG. 24A subsequent toentanglement of the first and second fiber layers, in accordance withaspects hereof;

FIG. 24C depicts the assemblies of FIG. 24B having a trimming operationperformed, in accordance with aspects hereof;

FIG. 25A depicts an exemplary dimensional-offset scrim, in accordancewith aspects hereof;

FIG. 25B depicts a cross-section of the exemplary dimensional-offsetscrim of FIG. 25A, in accordance with aspects hereof;

FIG. 25C depicts the cross-section of FIG. 25B positioned between firstand second fiber layers, in accordance with aspects hereof;

FIG. 25D depicts the assembly of FIG. 25C subsequent to entanglement ofthe first and second fiber layers, in accordance with aspects hereof;

FIG. 26 depicts an exemplary article of footwear formed, at least inpart, by fiber-binding particulates in a desired pattern between twofiber layers, in accordance with aspects hereof;

FIG. 27 depicts an embroidered scrim, the embroidery imparting a desireddesign to a manufactured footwear article, in accordance with aspectshereof;

FIG. 28 depicts a laser or die-cut film scrim that imparts a desireddesign to a manufactured footwear article, in accordance with aspectshereof;

FIG. 29 depicts a knit collar being attached to a footwear upper duringentanglement, in accordance with aspects hereof;

FIG. 30 depicts a close-up view of the connection between the knitcollar and the upper of FIG. 29, in accordance with aspects hereof;

FIG. 31 depicts a variety of scrims and elements being fiber-boundtogether to create a desired manufactured footwear component, inaccordance with aspects hereof;

FIG. 32 depicts a configuration for manufacturing fiber-bound engineeredmaterials utilizing individual pre-sized, cut fiber layers, inaccordance with aspects hereof;

FIG. 33 depicts a configuration for manufacturing fiber-bound engineeredmaterials utilizing pre-sized, cut fiber layers provided as a continuousroll, in accordance with aspects hereof; and

FIG. 34 depicts a configuration for manufacturing fiber-bound engineeredmaterials utilizing loose cut fibers, in accordance with aspects hereof.

DETAILED DESCRIPTION OF THE INVENTION

Fiber binding is a process in which fibers from one or more fiber layersare entangled to form a complex composite material that is engineeredfor an article. The engineered material may have structures entrappedwithin the fiber layers to achieve an engineered quality for a specificarticle, such as a shoe or piece of apparel. In the context of a sportshoe, the fiber-bound material may include, by way of example only, anentrapped high-tensile cable element to transfer lace loads from athroat to a sole, entrapped foam-structure elements that provide paddingin a heel collar, entrapped fusible-material elements that form into arigid heel stay and/or a water-resistant membrane in the toe box, and/orentrapped hardware elements that serve as a lacing structure. All of theelements/components are integral to the engineered material as they areentangled with and/or by the one or more fiber layers without additionalcutting, fusing, or sewing operations being performed.

The one or more fiber layers serve as a platform and a binder onto whichadditional materials are secured to build a unique hybrid compositematerial that is consolidated into a single material throughentanglement. The entanglement causes the fibers of the one or morefiber layers to physically interact with and lock in the additionalmaterials to create a cohesive and complete material that can be formedinto an article. The materials added to the fiber layer(s) and thematerials forming the fiber layer(s) can be deliberately and/orstrategically placed to achieve an intended functional characteristic atan intended relative location that allows for a highly engineeredmaterial to be formed as a complex composite that is consolidated into asingle material through entanglement.

The resulting fiber-bound engineered material is light-weight,comfortable, customized, and efficient to manufacture. Fiber-boundengineered materials can be applied to an unlimited number of industriesand articles. For example, in sport apparel, an engineered bra havingfiber-bound clasps, rings, padding, and support elements may be formedas a single material that is light-weight, breathable, and comfortable.Fiber-bound engineered material also may be utilized, for instance, infootwear or apparel to create outer-facing layers and inner-facinglayers having different properties, for instance, to create a moisturedifferential capable of transporting moisture away from the inner-facinglayer. For instance, the content and/or linear mass density measurement(denier) of the polymers comprising the fibers on the outer-facingsurface (first surface) and the inner-facing surface (second surface) ofan article may be changed to alter the relative moisture-transportproperties thereof. Fiber-bound engineered material also may form a shoethat has integral engineered characteristics, such as lock down,elasticity, breathability, traction elements, and padding. Fiber-boundengineered materials also may be processed into synthetic leather thatmaintains the engineered characteristics while further being classifiedas engineered synthetic leather. Therefore, this material that is highlyefficient to manufacture and also has an infinite degree of customengineering available, may replicate synthetic leather in an engineeredmaterial form.

Fiber-bound engineered materials have a signature look derived from thefiber layer(s) forming the fiber binding. Fiber transitions betweenintegral elements of a fiber-bound engineered material contribute tothis distinctive appearance. Regardless of top coats and post processes,a fiber-bound engineered material is distinctive in appearance due tothe fiber binding that serves as a lattice maintaining elements thatform or are entrapped within the fiber-bound engineered material.

Engineered materials are materials that provide an intendedcharacteristic at an intended relative location for an article to beformed therefrom. This is in contrast to stock materials. A stockmaterial merely provides characteristics without regard to intendedlocation(s) of the characteristics within an article to be formed. Assuch, with a stock material the article to be formed is manipulated toobtain a chosen characteristic at an intended relative location for thearticle. This manipulation may include combining pieces of the stockmaterial(s) in different orientations and locations to achieve anintended overall characteristic profile (e.g., a functionalityfingerprint that is unique to the collection of elements and relativeposition of those elements). The combining of pieces of stockmaterial(s) introduces waste from forming the pieces (e.g., cuttingscrap), it inserts inefficiencies (e.g., additional manufacturing stepssuch as sewing and bonding and/or more opportunities for manufacturingerrors to occur causing a higher scrap rate), it inserts unintendedcharacteristics to the article (e.g., joints between combined materialsthat interrupt transitions between material characteristics), it limitsarticle design options, and it limits comfort and fit of the resultingarticle.

Engineered materials can include at least knit manufactured materials,woven manufactured materials, braided manufactured materials,manufactured materials formed using tailored placement of fibers,deposition-formed manufactured materials, molded manufactured materials,injection-formed manufactured materials, compression-formed manufacturedmaterials, expansion-formed manufactured materials, and reduction-formed(e.g., cutaway, dissolved or milled) manufactured materials. Each of theengineered materials can be formed utilizing different techniques,different processes, different materials, and/or different machines,which can impart different characteristics, uses, and costs. Oneengineered material may not be substituted for another engineeredmaterial in all use scenarios. This is, in part, a result of articledesign, needs, and usage. Therefore, while engineered materials aregenerally known, each engineered material provides its own advantagesfor specific implementations.

Aspects herein contemplate a fiber-bound engineered material. Thefiber-bound engineered material is an engineered material that providesan intended characteristic at an intended relative location for anarticle to be formed therefrom.

Fiber-bound (or fiber-bind) refers to maintaining materials in a definedrelative position with fiber binding. Fiber binding is a physicalentanglement of fibers that generates a mechanical connection. Fiberbinding may maintain a material in a defined relative position byentangling fibers of a fiber layer with fibers of the material to bemaintained. Fiber binding also may maintain a material in a definedrelative position by entangling fibers of a first fiber layer on a firstside of the material to be maintained with fibers of a second fiberlayer on a second side of the material to be maintained (e.g., encasingor entrapping the material to be maintained). Fiber binding further maymaintain a material in a defined relative position by entangling fibersof a first fiber layer on a first side of the material to be maintainedwith fibers of both the material to be maintained and a second fiberlayer on a second side of the material to be maintained. Similarly,fiber binding contemplates a multi-dimensional entanglement of fibers.Therefore, for the examples provided above wherein the fibers of a firstfiber layer are entangled with another set of fibers, it is contemplatedthat the other set of fibers are also entangled with the fibers of thefirst fiber layer.

Fiber entanglement, the physical interaction of fibers that results in amechanical connection between the entangled fibers, may be accomplishedwith a variety of techniques. Fiber entanglement may be accomplishedthrough the physical movement of a first fiber into contact with asecond fiber to cause a frictional and/or mechanical intertwinement. Thephysical movement may be accomplished with one or more barbs of a barbedneedle, one or more sharp tips of a structured needle (e.g., innon-wovens), and/or a focused stream of fluid (e.g., liquid and/or gas).

Barbed-needle entanglement has a needle-like element comprised of one ormore barbs that pass into or through a collection of fibers to cause aninterlocking of the fibers. For example, a technique commonly referredto as needle felting relies on entanglement with barbed needles. In thisexample, a barbed needle (or plurality of barbed needles) moves up anddown on a collection of fibers with the barbs of the needle(s) catchingfibers and causing a physical interaction between the fibers. The up anddown movements of the barbed needles are effective to move fibersupwards and downwards within the fiber collection causing a fiber at ornear a first surface to move towards fibers at or near an oppositesurface of the collection and vice versa. A traditional sewing needlenot having barbs to intentionally cause a movement of fibers merelycauses puncture of the fibers and does not result in entanglement ascontemplated herein. For example, sewing of a fiber layer with atraditional sewing needle is joining through stitching and not joiningthrough entanglement.

Structured needle entanglement includes a needle element having one ormore sharp tips that create a particular structure as the tip(s) passinto or through a collection of fibers. For instance, a structuredneedle may create a diamond structure or a loop structure uponentanglement. In structured needle entanglement, the profile of theneedle element is such that while the needle element is passed through acollection of fibers, a structure is also created, the shape of thestructure being based on the profile of the needle tip(s). By way ofexample only, a structured needle may comprise a fork-like structurehaving two prongs with a gap there between wherein upon passing throughthe collection of fibers, at least a portion of the collection of fibersaligns with the gap permitting formation of a structure coincident withthe profile of the needle elements.

Fluid entanglement relies on high-pressure jets (e.g., streams) ofliquid (e.g., water) to pass into or through a collection of fibers andphysically move portions of one or more fibers. The liquid jet streammay pass in a single direction or the stream may pass in multipledirections to achieve different entanglements. Additionally, the fluidstream conditions and parameters can be altered to change the resultingentanglement. For example, adjustment of pressure, stream size,direction, speed, number of interactions, stream shape, and the like canbe adjusted to alter the resulting entangled fibers. For example,increases in stream pressure can result in splitting one or more fibersduring the entanglement process which can generate greater entanglementsurfaces and a change in fiber properties. Additionally, fluidentanglement may be effective to incorporate one or more structures ortextures into the entangled fiber layer. For example, a drum about whichentanglement may occur may have one or more textures or structures thathelp define a resulting texture or structure resulting from entanglementabout the drum. The drum may include a plurality of apertures that causeformation of apertures in the fiber layer(s) during entanglement. Also,the drum may include a variable surface that imparts a texture to thefiber layer(s) as part of the entanglement process. Fluid entanglementalso may be referred to as spunlacing, in an exemplary aspect. Oneexemplary form of fluid entanglement wherein streams of water areutilized commonly is referred to as hydroentanglement.

The entanglement process may be performed uniformly or it may beperformed zonally. In a first exemplary aspect, entanglement applies acommon entanglement condition across an entire collection of fibers.This uniformity may provide a simplified entanglement process. As willbe described hereinafter, it is contemplated that other variables (e.g.,materials, position of materials, relative position of materials, andsize, thickness, weight, and/or density of materials) may be adjusted toachieve an engineered material while still implementing a uniformentanglement process.

A variable entanglement process may include a zonally-controlledentanglement. For example, a first area of a collection of fibers mayreceive entanglement having a first set of parameters (e.g., duration,pressure and/or cycles) while a second area of the same collection offibers may receive entanglement having a second set of parameters. Theresulting engineered material may have different characteristics formedby fiber entanglement in the first area than those formed by fiberentanglement in the second area. For instance, at a first area of acollection of fibers, a hydroentanglement characteristic may be at ahigh pressure and duration that is effective to split the fibers whilein a second area of the collection of fibers the pressure and durationmay be reduced such that the fibers do not split. In this example, thefirst area may have higher tear strength, greater fineness, and lesserloft relative to the second area, for example.

The variability in entanglement characteristics may be manuallycontrolled by an operator of an entanglement machine and/or thevariability in entanglement characteristics may be automated based oncomputer-controlled entanglement equipment. For example, it iscontemplated that a vision system or other identification device may beused to identify a component and to determine an appropriate variableentanglement to provide. In this example, a position orientation, size,and article type may be determined by the vision system or otheridentification device and used to control the characteristics of theentanglement and position of the entanglement relative to the article. Acomputer may store one or more programs having pre-determinedinstructions for implementing a variable entanglement process based on adetermined article and/or position of the article.

Another variable that may be adjusted to achieve a difference inentanglement characteristics is the barbed needle utilized forbarbed-needle entanglement. The number of needles, the size of theneedle(s), the shape of the needle(s), and the barb size/shape/number ona particular needle also may be adjusted for different materials and/orlocations. For example, different needle types/sizes/shapes may be usedon a common collection of fibers to achieve different entanglementresults. For instance, the selection of a needle may depend, at least inpart, on the material, construction, and/or size of a scrim (i.e., anelement maintained in a relative position by one or more fiber layers asa fiber-bound element, as more fully described below) placed at a givenlocation of a collection of fibers. Therefore, in a first location ofthe collection of fibers, the first location including a first scrimhaving a first characteristic, a first barbed needle may be selected. Ina second location of the collection of fibers, the second locationincluding a second scrim having a second characteristic, a second barbedneedle may be selected. The difference in the first and second barbedneedles may be to achieve a different entanglement, to improveentanglement efficiency, and/or to improve manufacturability (e.g.,limit needle breakage while still minimizing needle size). Further yet,it is contemplated that a collection of barbed needles may be bundled asa common entanglement tool. How and in what combination the barbedneedles are bundled also may contribute to zonal manipulation of thefibers through entanglement.

In a specific example, it is contemplated that a needle entanglementmachine may have a collection of barbed needles extending along amaterial width. The needles may be varied in one or more characteristics(e.g., diameter, barb size, barb direction and/or barb number) dependingon a relative location along the material width. For example, arepeating pattern of needle characteristics may be used to form arecurring striation of entanglement patterns along the material width.In practice, this may be used such that each width-wise striationreflects an area in which an article is to be formed. For example, alonga single striation, a toe-end on a right portion of the striation and aheel-end on a left portion of the striation may have differententanglement characteristics based on scrim selection and/or fiberselection at the relative location. As such, a rolled good may be formedwith zonal attributes resulting from entanglement along a roll widththrough varied barbed needle characteristics.

Yet another variable that may be adjusted to achieve a difference inentanglement characteristics is the profile of the needle element(s)utilized for structured-needle entanglement. The number of needles, theprofile of the needle element(s), and the needle elementsize/shape/number on a particular needle also may be adjusted fordifferent materials and/or locations. For example, different needleelements/sizes/shapes may be used on a common collection of fibers toachieve different entanglement results. For instance, the selection of astructured needle (and, thus, its structured needle elements) maydepend, at least in part, on the material, construction, and/or size ofa scrim (i.e., an element maintained in a relative position by one ormore fiber layers as a fiber-bound element, as more fully describedbelow) placed at a given location of a collection of fibers. Therefore,in a first location of the collection of fibers, the first locationincluding a first scrim having a first characteristic, a firststructured needle may be selected. In a second location of thecollection of fibers, the second location including a second scrimhaving a second characteristic, a second structured needle may beselected. The difference in the first and second structured needles maybe to achieve a different entanglement, to improve entanglementefficiency, and/or to improve manufacturability (e.g., limit needlebreakage while still minimizing needle size). Further yet, it iscontemplated that a collection of structured needles may be bundled as acommon entanglement tool. How and in what combination the structuredneedles are bundled also may contribute to zonal manipulation of thefibers through entanglement.

Fiber Layer

A fiber is a slender and significantly elongated natural or syntheticpliable material. A fiber, in an exemplary aspect, has a length that isat least 100 times a width/diameter of the fiber. However, it iscontemplated that the ratio of diameter/length may be less than 1:100.For example, in some instances a fiber may be formed from a cut segmentwhere prior to being cut, the at least 100 times length-to-diameterratio was satisfied, but subsequent to cutting the original fiber, asmaller multiple is measured. An example may be protein-basedstrand-like materials, such as animal hide/skin, which may have asmaller ratio, but still may be considered a fiber. Other natural orbio-synthetic fibers are contemplated, such as polymeric fibers fromplant, animal, and/or microbial sources. Polypeptide polymers areprotein-based fibers. Examples of polypeptides include, but are notlimited to, collagen, keratin, silk, wool, cashmere, and soy-basedfibers. Other contemplated natural fibers include, but are not limitedto, polysaccharide polymers such as cotton, rayon, ramie, and othercellulosic-derived compounds. In an additional example, a fiber is anextruded composition comprising a hydrocarbon-based polymer. Forexample, a thermoplastic may be extruded as continuous filaments thatare fibers for purposes of the present application. A compositionforming a fiber may consist essentially of, or be comprised of, any ofthe following non-limiting examples: thermoplastic polyurethane (TPU),polyurethane, polyesters, polyamides, polyolefins, polycarbonates,and/or co-polymers thereof. Additional materials are contemplated aswell, such as aramids, glass, cellulosic materials, carbon, metals,minerals, polyacrylonitriles, and the like. Further, it is contemplatedthat a fiber may consist essentially of any of the contemplatedmaterials, or a fiber may be a composition comprising the contemplatedmaterials in combination with additional materials (e.g., protein-basedwith a polymer coating), such as additives, fillers, coatings,treatments, and the like. An additional listing of suitable “polymers”from which a fiber, fiber layer, scrim, scrim element, and the like maybe formed is included hereinafter.

A fiber may be interpreted to include filament, yarn, thread, string,cord, strand, and the like. Stated differently, a “fiber layer” may beformed from yarn, thread, cord, strand, and the like and still be afiber layer for purposes of the present application. The fiber may be acontinuous fiber or a staple fiber. Additionally, it is contemplatedthat a fiber may be a macro fiber or a micro fiber. For example, a fibermay have a linear mass density measurement expressed as denier perfilament (“dpf”) of 1 to 9 dpf. Alternatively, a fiber may have a linearmass density measurement expressed as a denier (or denier per filament)of 0.001 to 0.999 dpf. In some examples, a fiber may have a first dpfwhen formed into a collection of fibers (e.g., a batting layer) and thefiber may have a much smaller dpf subsequent to entanglement (e.g.,chemical or mechanical fibrillation). For instance, the fiber may splitinto a greater number of fibers during entanglement. A fiber may be anisland-in-the-sea construction such that a trigger (e.g., chemical,heat, light, and/or water) may be applied to dissolve the sea portion orotherwise break up the original fiber. For example, a staple fiber maystart at a size between 1 and 9 dpf and end with a size of between 0.005and 0.1 dpf, in some examples. The reduction may be accomplished thoughdissolution of the sea by solvent reduction or solubilizing portions,such as polyvinyl alcohol dissolved with water. Additionally, segmentedpie construction may be leveraged to achieve a reduction in fiber size.It is contemplated that the fibers may reduce from 3 dpf to 0.05 dpf.This too may be accomplished through techniques like solvent reduction.This change in fiber count and/or dpf may be useful to change one ormore characteristics of the collection of fibers. For example,microfibers too fragile to form into a batting may result from thereduction in dpf (e.g., by splitting and/or reaction) that is desired inthe final article.

Additionally, it is contemplated that a fiber may be measured at across-section in a traverse direction relative to a longitudinal lengthof the fiber. The cross-sectional width in the traverse direction ishereinafter referred to as a “fiber width.” It is contemplated thatsuitable fibers may have a fiber width of any range, but in an exemplaryaspect a fiber has a fiber width of 200 microns to 100 nanometers.Another contemplated fiber width range includes 100 microns to 100nanometers. Yet another contemplated range for fiber width is 25 micronsto 0.01 microns. Another contemplated fiber width range is 10 microns to0.01 microns. A macro fiber has a fiber width range of 10 microns to 200microns. A micro fiber has a fiber width range of 10 microns to 1micron. A nano fiber has a fiber width that is less than 1 micron (e.g.,0.9999 microns to 100 nanometers). Exemplary materials contemplated mayhave fiber widths such as a cotton fiber at about 20 microns, a woolfiber between 10 and 25 microns, a nylon fiber between 12 and 16microns, an apparel polyester fiber between 12 and 25 microns, and aglass fiber at about 150 microns.

A collection of fibers may be comprised of a variety of fibers. Thevariety of fibers may be different based on any characteristic, such asmaterial composition, dpf, fiber width, size, cross-sectional shape inthe traverse direction (e.g., round, ovoid, triangular, rectilinear,lobed, dogbone, or hollow), a longitudinal profile (e.g., flat,straight, wavy, crimped, smooth, scaled, branched, or irregular) and/orlength. The collection of fibers may be a non-uniform distribution ofdifferent fibers (e.g., a zonal distribution for the collection) or arelatively consistent distribution (e.g., a homogeneous collection ofdifferent fibers). Further, a collection of fibers may vary based onposition in an X-Y plane and/or in a Z direction. For example, it iscontemplated that a first fiber may be located at a first position of abatting layer through the thickness of the batting layer and a secondfiber that is different from the first fiber may be located at a secondposition of the batting layer through the thickness of the battinglayer. In an alternative example, it is contemplated that a firststratum of a batting material includes a first fiber and a secondstratum of the batting layer includes a second fiber that is differentfrom the first fiber. It is contemplated that both X-Y position andstratum variations in fiber type may be implemented to achieve anengineered material.

The fibers may be constructed into a variety of forms, such as anonwoven material. A nonwoven fiber material may be referred to asbatting in some examples. A nonwoven material is a material that isneither woven nor knit. Instead, a collection of fibers are heldtogether through mechanical and/or chemical interactions. An example ofa nonwoven material includes felt. Felt is neither woven nor knit.Instead, felt is a material where a collection of fibers aremechanically manipulated to form a mat-like material. However, felt isnot an engineered material in that traditional felt has uniformcharacteristics and it is unable to provide an intended characteristicat an intended relative location for an article to be formed therefrom.For example, when forming an article with felt, the orientation,position of a portion of the felt from a greater collection of the felt,or other functional characteristics of the felt are not accounted forwhen forming the article as the felt is substantially constant in itscharacteristics.

A plurality of fibers, as described above may be homogenous orheterogeneous, and may be formed as a nonwoven material that issometimes referred to as batting. Batting may be formed from a pluralityof strata. Each stratum may have a different or a similar composition offibers. Batting may be formed as a continuous material (e.g., a rolledgood) or it may be formed as a discrete element (e.g., batch goods).Therefore, as described throughout the present application, a fiberlayer may include a continuous material (e.g., a rolled batting layer)or a discrete material (e.g., a cut batting layer).

A continuous batting layer formed from a fiber layer may have differentcharacteristics in a width direction (e.g., traverse to a longitudinaldirection of the continuous batting layer). The continuous batting layermay also or alternatively have varied characteristics in thelongitudinal direction. For example, a repeating pattern ofcharacteristics in the longitudinal direction is contemplated forforming a plurality of similar articles in a non-batch process.Alternatively, a gradient change in characteristics is contemplated inboth the traverse and the longitudinal directions. This transitionalcharacteristic change may avoid binary transitions in characteristicsfor a resulting article. Similarly, it is contemplated that variationsmay occur in the longitudinal and/or traverse directions at any stratum(e.g., in the Z direction). The characteristics of the continuousbatting layer may include, without limitation, fiber composition, fibercharacteristic, batting thickness, and the like.

A batch batting layer formed from a fiber layer may have differentcharacteristics in an X, Y, and/or Z direction. Changes incharacteristics of the batch batting layer may be binary in nature(e.g., an identifiable change from a first characteristic to a secondcharacteristic) or gradual in nature. The characteristics of the batchbatting layer may be, without limitation, fiber composition, fibercharacteristic, batting thickness, fiber density in a stratum, and thelike.

Another fiber layer concept is a net-shape fiber layer. A net-shapefiber layer is a minimal waste fiber layer that substantiallyconstitutes the entire article perimeter to be formed. As a result,following entanglement, trimming and cutting operations may be minimizedresulting in minimized waste generation. Net-shape fiber layers mayinclude one or more manufacturing portions. Manufacturing portions areelements that exceed a true net-shape, but provide handling and materialmovement capabilities to manipulate the parts. For example, tabs orother elements may be included to allow for positioning, picking,identifying, and/or finishing. In aspects, and as more fully describedbelow with reference to FIGS. 32 through 34, a net-shape fiber layer maybe utilized with a reusable carrier screen during manufacturing.

The fiber selection also is contemplated to include a reflectivematerial. For example, a mylar or other material having reflectivesurfaces may be incorporated to provide heating and/or coolingcharacteristics. Reflectivity of a material may be incorporated at anylevel of a fiber-bound engineered material (e.g., fiber level, battinglevel, scrim level, or top coating level).

It is also contemplated that one or more macro additives may beincorporated into a fiber layer. For example, a particulate or powderform of any material provided herein may be incorporated with one ormore fiber layers. For example, acrylic polymers that are expandable maybe incorporated with a fiber layer before or after entanglement. Theincorporation of the particulate/powders materials can be used tosupplement the characteristics of the fibers. For example, a lower-costfiber may be used that can be enhanced with particulate integrationrelative to a higher-cost fiber having a similar characteristic withouta supplemental particulate. The particulate contemplated includes atleast the polymers listed herein.

It is contemplated that an engineered material may be formed throughvariations in characteristics of a fiber layer. The variations incharacteristics may be determined, at least in part, through fiberselection and position, entanglement characteristics, and/or thecombination thereof. Further, as will be described in greater detailhereinafter, additional processing to the engineered fiber layer maycreate intended characteristics at an intended relative location of thefiber layer for an article to be formed therefrom. For example,application of a trigger (e.g., thermal energy, light (UV, IR, orvisible), sonic, plasma, E beam, radio frequency, chemicals, and/orwater) to specific portions of the fiber layer may generate anengineered material. Alternatively, application of a trigger tosubstantially the entire fiber layer may cause a change in specificfibers (or other additives) that have been non-uniformly (e.g.,intentionally) placed with respect to the fiber layer. An example of theformer includes selective application of one or more liquid chemistries(e.g., a hardener) to achieve a different characteristic in the fiberlayer at the location of application relative to locations in which aliquid chemistry is not applied. An example of the latter includesselectively placing fibers able to melt (or soften) at a giventemperature in a first area and fibers that do not melt (or soften) atthe same temperature in the second area. As the entire fiber layer isexposed to the given temperature, only those locations comprising thefiber that melts (or softens) at the given temperature take on adifferent characteristic resulting from the melting (or softening) ofthe fibers, in this example. As will be provided throughout, additionaltriggers, materials, placements, and combinations will be described andare applicable to aspects hereof.

Fusible fibers, such as thermoplastic polymer fibers having at least oneof a melt temperature and a softening temperature below at least one ofa melt temperature, a softening temperature, and a decompositiontemperature of other materials forming the fiber-bound engineeredmaterial, may be leveraged to adjust characteristics of a fiber layer.Application of the fusible fibers may be through integral incorporation(e.g., blending of fibers) with the fiber layer or it may be throughoverlaying portions of the fiber layer with fusible fibers thatsubsequently are entangled therewith. Fusible fibers may be used to forma transparent or translucent portion of a fiber-bound engineeredmaterial. For example, heat may be applied to a fiber layer subsequentto entanglement to form the translucent or transparent window portion,which may visually expose a scrim (e.g., having a particular colorationand/or structure) or other underlying element while still binding theunderlying element. Fusible fibers also may be varied to providedifferent measures of flexibility. For example, a type of fusible fibermay be selected based on location. Fusible nylon, when formed oractivated, may remain flexible whereas polyester when fused may becomestiff. Therefore a base fiber, such as a microsplit fiber, may becombined in a first region (e.g., a shoe toe region) with fusible nylonto form a flexible portion and with fusible polyester in a second region(e.g., a shoe heel region) to form a relatively rigid portion.

Once the fusible fibers are activated (e.g., fused), a distribution offusible fibers can be determined to allow a change in overall porosity(e.g., throughout a thickness of the fiber layer) or just a surfaceporosity. This determination in fusible fiber distribution allows forformation of portions that are water resistant, water repellant, windresistant, abrasion resistant, and the like. For example, fusible fibersproximate a first surface of a fiber layer may join together and make acontinuous, less permeable amalgamation to increase resistance to waterpenetration or the first layer may have a fusible fiber distributionthat forms a discontinuous, more porous amalgamation that is moresusceptible to air and water permeability.

Characteristics of a fiber, such as modulus of elasticity, are measuredpre-entanglement. Once entangled, measures of individual fibers areaffected by the entanglement process and/or mechanical connections withadjoining fibers.

Scrim

A scrim is an element maintained in a relative position by one or morefiber layers as a fiber-bound element. A scrim may be a textile (e.g.,knit, woven, braided, embroidered, nonwoven, or direct-fiber placedstructure), a non-fibrous material (e.g., film, sheet, extruded element,molded element, deposition formed, expansion formed, or compressionformed material), and/or a component (e.g., a zipper, snap, buckle,hook, loop, sensor, wire, fiber optic, bladder, tube, cord, or cablecomponent). A scrim may be formed from a variety of materials asindicated hereinafter in detail and by example immediately following.The materials contemplated include organic and synthetic materials. Forexample, a scrim may be formed from any of the following non-limitingmaterials including polypeptide-based materials (e.g., animal hide,wool, or feathers), plant or cellulosic-based materials (e.g., cotton orhemp), carbon, minerals, aramids, glass, metals, TPU, PU, polyesters,polyamides, polyolefins, polypheneylens, polystyrenes, polyvinyls, ABS,and/or polycarbonates, as well as co-polymers of the polymers. A scrimmay be formed from recycled or repurposed scrap, for instance, forming asheet from which the scrim may be formed. Further, a scrim may be in theform of a tape or strip (a tape generally being more continuous than astrip of similar or different material).

A scrim may be a discrete element or it may be a collection of elements.For example, a first scrim may be a homogeneous material (e.g., apolymer film) that when incorporated with at least one fiber layer, aswill be described hereinafter, forms an engineered material.Alternatively, a second scrim may be an engineered textile (e.g., a knitmaterial having at least one intended characteristic at an intendedlocation of the knit material) that when entangled and/or encased withor by one or more fiber layers forms an engineered material. Furtheryet, it is contemplated that multiple (and potentially different) scrimsmay be used in combination to form an engineered material whenentangled, entrapped and/or encased with or by one or more fiber layers.

As will be described in greater detail hereinafter, any combination ofthe fiber(s), fiber layer(s), and scrim(s) may be manipulated togenerate an engineered material. Exemplary manipulations may include,but are not limited to, selection of material, position, construction,order, secondary processes, and the like. As such, aspects hereincontemplate using fiber layer(s) and scrim(s) in any number, in anyposition, and/or in any combination to form a fiber-bound engineeredmaterial. Further, a fiber-bound engineered material may be used to formany article. For example, manipulations contemplated herein may beapplied to form an article of apparel (e.g., shirts, pants, shorts,under garment pants, bras, or socks), outerwear (e.g., coats, hats, orgloves), equipment (e.g., catching gloves, padding, protectiveequipment, or footwear inserts), footwear (e.g., shoes, sandals, boots,slides, mules, or loafers), and the like. Similarly, fiber-boundengineered material may be used in additional industries (e.g.,automotive, aerospace, medical, safety, packaging, furnishings, and thelike). Specific aspects hereinafter will describe articles of footwear,but it is understood that the concepts provided herein are not limitedin application to footwear, but instead may be applied across articlesand industries.

A scrim may be described as a continuous scrim, a partial scrim, a zonalscrim, an engineered scrim, a foundation scrim, or an element scrim. Aspecific scrim, as incorporated into a fiber-bound engineered material,may be classified as one or more of the different scrims. For example, acontinuous scrim may also be an engineered scrim. A continuous scrim mayhave a shape, size, and/or configuration that extends between two ormore portions of the article to be formed. For example, a continuousscrim, as used in a component forming an article of footwear, may extendfrom a medial side to a lateral side of the article of footwear, in anexemplary aspect.

A partial scrim may have a shape, size, and/or configuration for adiscrete portion of the article to be formed. For example, a partialscrim as used in a component forming an article of footwear may bepositioned in a toebox, a heel counter, a medial quarter region, alateral quarter region, a tongue, or the like.

A zonal scrim is a compounding of scrims, such as overlapping oroverlaying of multiple scrims. For example, a scrim having specificcharacteristics in a single direction may overlay another scrim having acharacteristic in a single but different direction to achieve one ormore multi-directional characteristics. As used herein, overlaid scrimsinclude adjacent scrims such that one or more layers may intervene butshare a common X and Y position regardless of Z-directional offset.Overlay does not, however, require all X and Y positions to be sharedbetween the overlaid materials (e.g., they may be of different sizesand/or shapes). By way of example and not limitation, a macro mesh scrimmay overlap a fine mesh scrim allowing a first side of a fiber-boundengineered material to have a macro texture and the opposite sideassociated with the fine mesh to have a more uniform texture. It is alsocontemplated that different scrims of different materials may beoverlaid. For example, a high tenacity material for limiting stretch maybe overlaid with a foam material for providing cushioning.

An engineered scrim is a scrim that provides an intended characteristicat an intended location of the scrim. For example, an engineered scrimmay be of a knit, woven, braided, nonwoven, extruded, molded, cast,deposited, expanded, reductions-formed, embroidered,tailored-fiber-placed, 3D-printed, film, sheet, or the like constructionthat has variable characteristics based on a location of the scrim and alocation at which the scrim is or will be incorporated into afiber-bound engineered material or article. For example, an engineeredscrim may change materials and/or construction based on location toachieve intended characteristics at the intended location.

A foundation scrim is a non-zonal scrim that has uniformity among one ormore characteristics on the scrim. Examples may include non-engineeredtextiles, non-engineered films/sheets, extrusions (e.g., thermoplasticor adhesive netting), or cast filament matrices that are not specific toa location and/or direction of where the scrim will be incorporated witha fiber-bound engineered material. An exemplary foundation scrim may beformed from a composition comprising a thermoplastic material having atleast one of a melt temperature and a softening temperature that islower than at least one of a melt temperature, a softening temperature,and a decomposition temperature of one or more fiber layers with whichthe foundation scrim is entangled.

An element scrim is an element or collection of elements that aretraditionally incorporated into a textile with bonding mechanismsdifferent from fiber binding (e.g., sewing, chemical adhesion, orfusing). Examples include, but are not limited to, zippers, hooks and/orloops, snaps, rings, electrical sensors, electrical components, lights,wires, fiber optics, fluid bladders, tubes, reinforcements, and thelike.

A scrim also may function as a structural carrier. For instance, whenutilized in the manufacture of an article of footwear, a scrim mayinclude one more lace apertures extending there through such that theresultant fiber-bound manufactured article will have enhanced structuralsupport surrounding the aperture locations.

A scrim also may function as a non-structural carrier. For instance, ascrim may function as a carrier for a plurality of particulates, forinstance, foam beads. In aspects, an adhesive (e.g., temporary adhesive)may be applied to a scrim uniformly or in a desired pattern, shape orconfiguration. A plurality of foam beads may be placed (strategically orat random) on the adhesive. Excess foam beads may be removed (forinstance, by blowing or the like). The scrim then may be entangled withone or more fiber layers such that the foam beads remaining on theadhesive are entrapped or encased by the fiber binding. The resultantmanufactured article will have a “bumpy” appearance with the surfacethereof being raised at the locations of the encased or entrapped foambeads when viewed relative to the surrounding surface.

In aspects, a carrier scrim may include indents or wells at thelocation(s) at which fiber binding of particulates is desired. In suchaspects, the Z-directional offset resulting from fiber binding of theparticulates may be controlled. Such Z-directional offset additionallymay be controlled by the size of the particulates utilized. Forinstance, in aspects, foam beads having a diameter of approximatelythree to five millimeters may be utilized, while in other aspects, foambeads having a diameter of 0.5 millimeters or less may be utilized. Anyand all such variations, and any combination thereof, are contemplatedto be within the scope of aspects hereof.

It is understood that particulates formed of materials other than foammay be utilized (e.g., a solid polymeric material). It is furtherunderstood that foam beads may be applied in a pre-foamed state andactivated pre- or post-entanglement, or may be applied already foamed.Still further, it is understood that although the particulates describedherein are discussed as having a diameter, particulates having a shapeother than spherical (e.g., oval, disc-like) may be utilized.

In aspects, a carrier scrim may not be utilized but rather particulatemay be applied directly to a fiber layer to be entangled with a scrim orother fiber layer. FIG. 26 illustrates an exemplary article of footwear2600 formed, at least in part, by fiber-binding particulates in adesired pattern 2610 between two fiber layers. A similar result may beobtained utilizing a carrier scrim.

A scrim also may function as a non-structural element. For instance, ascrim (such as a piece of foam material) may be die-cut or laser-cutinto a particular pattern (e.g., a lattice pattern) and strategicallyplaced and entangled with one or more fiber layers such that theresultant fiber-bound manufactured article will at least tactilelyexhibit the scrim pattern. FIG. 28 depicts an article of footwear formedfrom a first mesh scrim and colored second mesh scrim (the scrimsdiffering, for instance, in color), as well as a laser or die-cut filmscrim. As illustrated, the film scrim imparts a desired pattern to thearticle of footwear formed from the fiber-bound component.

Scrims may be formed from a variety of materials and/or techniques. Itis contemplated that different scrims, as will be described hereinafter,may be combined in an overlapping manner to achieve an intendedcharacteristic. For example, a macro mesh scrim may overlap a fine meshscrim allowing a first side of a fiber-bound engineered material to havea macro texture and the opposite side associated with the fine mesh tohave a more uniform texture. It is also contemplated that differentscrims of different materials may be overlaid. For example, a hightenacity material for limiting stretch may be overlaid with a foammaterial for providing cushioning.

Coloration may be integral with a fiber-bound engineered material. Forexample, fibers of one or more fiber layers may have a color profilethat is imparted into the material as entanglement consolidates thefibers. A scrim may have a color profile. The scrim may affect aperceived coloration of the fiber-bound engineered material as the scrimshows through the fiber binding. In some examples a fiber binding mayform a transparent or translucent structure through use of low-meltfibers that become transparent or translucent to depict an underlyingcoloration. Similarly, one or more colored fibers having a melttemperature, softening temperature, or degradation temperature above thelow-melt fibers may become encased/entrapped or suspended in a low-meltfiber amalgamation. Still further, it is contemplated that as a trimmingor unmasking operation occurs, one or more underlying materials may beexposed along with their associated coloration. Further yet, becausedifferent materials may be formed as a continuous and cohesive hybridmaterial, some materials may be colored with a coloration techniquewhile other materials may not be able to be colored with the samecoloration technique. This discrepancy in propensity to acceptcoloration can lead to hybrid coloration from a uniform application ofcoloration. As can be appreciated, a variety of coloration alterationsmay be achieved through material selection, placement, and/orprocessing.

In aspects, scrims may be coupled with another component of the articleto be manufactured prior to entanglement. For instance, a scrim intendedto be utilized to form an upper of an article of footwear may be adhered(e.g., stitched) to a secondary element (e.g., a knit ankle collar)prior to entanglement. In this instance, the scrim would no longer beplanar but rather would extend in the Z-direction at the location of thesecondary element. In aspects, the knit collar (secondary element) thenmay be masked over (e.g., with tape) and a fiber layer placed over themasked scrim/secondary element assembly and the assembly and the fiberlayer entangled. Depending on the location of the masking, the fiberentanglement may effectively hide the stitched seam making it difficultto ascertain from appearance alone how the secondary element wasattached. The stitched seam also may be reinforced through entanglementmaking the connection more robust and less susceptible to failure.

In aspects, secondary elements formed from processes other than fiberentanglement may be coupled with one another and/or a fiber-boundelement via fiber binding. For instance, FIG. 29 illustrates anexemplary article of footwear 2900 having an upper 2916 formed utilizinga laser or die-cut foam scrim 2910, along with a mesh scrim 2912. Theknit collar component 2914 has been attached to the rest of the upper2916 during entanglement, rather than by stitching. FIG. 30 illustratesa close-up view of the connection between the upper 2916 and the knitcollar 2914.

Various scrims and fiber layers may be strategically placed with respectto one another to create a variety of desired effects, the boundaries ofwhich are limited only by the imagination. For instance, FIG. 31illustrates a fiber-bound flat upper component 3100 of an article offootwear which has not yet been cut and assembled to form athree-dimensional upper. The fiber-bound component 3100 includes a meshscrim entangled with regions of first fibers, regions of second fibers3212, regions of third fibers 3214, and regions of a mixture of firstand second fibers 3216 on the surface that will be the exterior-facingsurface of the three-dimensional footwear article. Fly-wire cables 3218are entangled along what will become the medial and lateral sides of theupper. Loops of cables 3220 for use as lace supports have been leftun-entangled, as has a region of the mesh scrim. In the illustratedupper component, a silicone material 3220 has been screen printed overportions of the upper, for instance, to provide abrasion resistance.

In aspects, entanglement may occur in two directions (e.g., fibers of afirst fiber layer extending into (i.e., not all the way through) orthrough and entangling with fibers of a second fiber layer and fibers ofthe second fiber layer extending through and entangling with fibers ofthe first fiber layer). Such two-directional entanglement may result ina relatively uniform appearance of the resultant fiber-bound article(assuming substantial uniformity of the fiber layers and the scrim, ifpresent). In other aspects, entanglement may occur in only onedirection, for instance, fibers of a first fiber layer extending throughand entangling with fibers of a second fiber layer where fibers of thesecond fiber layer do not extend through to entangle with fibers of thefirst fiber layer. This single-directional entanglement also may resultin a relatively uniform appearance of the resultant fiber-bound article(assuming substantial uniformity of the fiber layers and the scrim, ifpresent). However, where the fiber layers exhibit different propertiesfrom one another (for instance, different coloration), strategic use ofsingle-directional and two-directional entanglement for a singlefiber-bound article may result in a desired pattern being formed on theresultant fiber-bound article. For instance, in the article shown inFIGS. 29 and 30, some portions of the mesh scrim have only beenentangled in one direction so that fibers of the first fiber layer showthrough and appear as polka dots on some areas on the upper.

Overview

A fiber-bound engineered material provides an intended characteristic(e.g., elasticity, cushioning, stiffness, air permeability, moisturecontrol, tenacity, feel, or insulation) at an intended relative locationfor an article to be formed therefrom using entangled fibers to maintainor create the intended characteristic at the intended location. Forexample, a first fiber layer comprised of a first plurality of fibers, ascrim, and a second fiber layer comprised of a second plurality of fibermay be formed as a component of an article of footwear. The component isat least formed by entangling the first plurality of fibers with thesecond plurality of fibers. This entanglement maintains the scrim in anintended relative location with respect to the first and second fiberlayers.

In some examples the scrim itself is formed from material that allowsfor mechanical engagement with one or more fibers from at least one ofthe first and second plurality of fibers. The mechanical engagement maybe an entanglement where fibers forming at least a portion of the scrimentangle with fibers of the first and/or second plurality of fibers. Themechanical engagement may include one or more fibers from the firstand/or second plurality of fibers passing into (i.e., not all the waythrough) or through a portion of the scrim. For example, if the scrimincludes an aperture (e.g., a negative space), fibers from the first andsecond pluralities of fibers may entangle around and through theaperture. Mechanical engagement may include one or more fibers from thefirst and/or second plurality of fibers extending into the scrim andphysically interacting with the scrim. For example, the scrim may becomprised of a foam material that allows penetration or mechanicalengagement of one or more fibers from the first and/or second pluralityof fibers during an entanglement operation. An interstitial spacebetween adjacent fibers may provide additional or alternative locationsfor interlocking of fibers and a scrim.

In some examples, the scrim is maintained in a position without beingentangled with the fibers. For example, in a first aspect, the scrim maybe impenetrable and the plurality of fibers may be entangled around thescrim, but not through the scrim. If the scrim is of an appropriateshape (e.g., tubular or round), the scrim element may be able to rotateor be moved within the defined location encasing the scrim. Inalternative aspects, if the scrim is of an appropriate shape (e.g.,non-symmetrical or discrete elements), the scrim element may bemaintained in the specified location and may be non-movable within theencasement position.

Subsequent to entangling the one or more fiber layers to maintain thescrim, through encasement and/or mechanical engagement, a fiber-boundengineered material is formed that provides an intended characteristicat an intended relative location for a component of an article offootwear. The component may be a discrete element of the article offootwear or the component may be a whole portion (e.g., a shoe upper) ofthe article of footwear. In an example where the component is a shoeupper, the location of the intended characteristic(s) may be relative tothe shoe upper. As such, specific characteristics may be formed atlocations of a shoe upper to be formed from a fiber-bound engineeredmaterial.

Additional materials may be integrated or included. For example, a film,such as a metallic film, may be applied to one or more portions of afiber-bound engineered material. The metallic coating may providereflective features, such as heat retention or heat reflection relativeto an article formed with the metallic coating. Additional coatings arecontemplated that achieve supplemental engineered characteristics, suchas water repellency, abrasion resistance, coloration, and the like. Thecoating may be applied universally to the material or zonally to thematerial.

Footwear

Turning to FIG. 1 illustrating an exemplary article of footwear, a shoe100, in accordance with aspects hereof. An article of footwear isreferred to as a shoe herein for simplicity, but it is understood thatan article of footwear may include a sandal, a slipper, a dress shoe, acleat, a running shoe, a tennis shoe, a loafer, a boot, a slide, a mule,and the like. The shoe 100 is exemplary in nature to illustrate relativeterminology and it is not intended to be limiting in scope of conceptsprovided herein. It is understood that a component of an article offootwear may or may not include the elements illustrated with the shoe100. Further it is understood that alternative configurations, styles,and relative sizes from those illustrated in connection with the shoe100 may be implemented in a component for an article of footwear.

The shoe 100 is comprised of an upper 102 and a sole 104. The upper 102is a foot-securing portion of the shoe 100. The upper 102 traditionallyforms a foot-receiving cavity into which a wearer inserts his/her footto be secure to the sole 104. The sole 104 is a ground contactingsurface of the shoe 100. The sole 104 may comprise an outsole, amidsole, and/or an insole. The outsole, when present, forms the groundcontacting portion of the sole 104 and is typically abrasion resistantor adapted for the surface on which the shoe 100 is intended to be worn.The midsole, when present, may provide impact attenuation for the shoe100, in an exemplary aspect. The insole, when present, may provide afoot-facing portion of the sole 104. It is understood that one or moreportions of the sole 104 may be combined without differentiation ordistinction. Additionally, it is contemplated that the specific portionsof the sole 104 may be omitted altogether, in some aspects.

The shoe 100 has a toe end 106, a heel end 108, a forefoot opening 110,an ankle opening 112, and a tongue 114. As best seen in FIG. 2 depictinga plan view of the shoe 100, in accordance with aspects hereof, the shoe100 is further comprised of a medial side 109 and a lateral side 107.Further the shoe 100 is comprised of a vamp portion 118, a quarterportion 120, a throat edge 122, and an internal surface 116.

The shoe 100 may be described based on the relative position of thevarious portions. For example, the quarter portion 120 extends generallyfrom the throat edge 122 down toward the sole 104 on the lateral side107. Similarly, the shoe 100 is comprised of a reciprocal quarterportion on the medial side 109. Further, a heel portion extends betweenthe medial side 109 and the lateral side 107 around the heel end 108.The shoe 100 has a toe box region that extends from the vamp 118 towardthe toe end 106 between the medial side 109 and the lateral side 107.The throat edge 122 extends around the forefoot opening 110 (FIG. 1) onthe medial side 109 and the lateral side 107 across the vamp 118, inthis example. A lace structure may extend across the forefoot opening110 (FIG. 1) to tighten the upper 102 (FIG. 1) about a wearer's foot.The tongue 114 may extend from the vamp 118 through the forefoot opening110 (FIG. 1) toward the ankle opening 112 and provide support to theshoe 100 and/or cushioning for the wearer as the lacing mechanismextends over the wearer's forefoot, in an exemplary aspect.

Fiber-Bound Engineered Material Construction

FIGS. 3A through 6B depict a sequence for constructing an exemplaryfiber-bound engineered material, in accordance with aspects hereof.(Additionally, FIGS. 32-34, discussed more fully below, depict aconfiguration for constructing an exemplary fiber-bound engineeredmaterial utilizing carrier screens, in accordance with aspects hereof.

FIG. 3A depicts a cut fiber layer 300 comprised of a plurality of fibers302 as a non-woven structure. The fibers 302 are depicted forillustration purposes, but it is understood that the fibers 302 may havedifferent concentrations, densities, sizes, interactions, and forms fromthat which is illustrated in schematic style in FIG. 3 and other FIGS.hereinafter. Additionally, while the cut fiber layer 300 is depicted asa batch style element, it is merely representative in nature and insteadcould be depicted as a continuous element (e.g., a rolled good).Therefore, the cut fiber layer 300 is merely exemplary in nature and isnot limiting as to size, shape, or configuration as to aspects providedherein.

FIG. 3B depicts a cross-sectional view of the cut fiber layer 300 alongcutline 3B of FIG. 3A, in accordance with aspects hereof. The cut fiberlayer 300 has a first side 304 and a second side 306. While depicted asa single stratum formed from the fibers 302, it is contemplated that thecut fiber layer 300 may be comprised of a plurality of discrete ortransitional strata, as described hereinabove. The cut fiber layer 300is depicted as having a thickness extending between the first side 304and the second side 306. However, the thickness depicted is forillustration purposes and is not limiting in nature.

FIG. 3C depicts a fiber layer 301 much like FIG. 3B; however, the fibers303 of the fiber layer 301 are “continuous” fibers, in accordance withaspects hereof. A continuous fiber is a fiber having a length that isgreater than 200 times a traverse width of the fiber. Aspects hereincontemplate fiber layers having cut fibers and/or continuous fibers.

FIG. 3D depicts a continuous fiber layer 305 forming a fiber layer as arolled good, in accordance with aspects hereof. As described herein, afiber layer may be a batch layer having a discrete size or the fiberlayer may be a continuous textile, as depicted in FIG. 3D. As alsodepicted, one or more article profiles 307, such as an upper patternprofile, may be formed on the continuous fiber layer 305. It iscontemplated that a single scrim may span across multiple articles to beformed. For example, a scrim may be applied to a rolled good fiber layersuch that the scrim extends across a traverse direction or alongitudinal direction to be incorporated within multiple footwearuppers. For example, the article profiles 307 depicted include multipleshoe uppers in the longitudinal direction. A common scrim may be placedin a longitudinal direction such that one scrim is incorporated intomultiple shoe uppers when removed from the continuous roll.

FIG. 4A depicts a scrim 400 positioned on the fiber layer 300, inaccordance with aspects hereof. The scrim 400 is exemplary in nature andis not limiting. The scrim 400 is a continuous and engineered scrim. Thescrim 400 forms, in part, an upper for an article of footwear having atoe end 406 and a heel end 408. The scrim 400 further is comprised ofmidfoot engineered elements 402, such as a high tenacity (e.g., lowstretch) material effective to transfer a lace load from a throatopening towards a sole structure when formed as a shoe upper. The scrim400 also includes heel end engineered elements 404. The heel endengineered elements 404 may be stiffening members to reinforce a heelregion when formed into a shoe upper, in aspects hereof.

The scrim 400 may be formed as a knit, woven, nonwoven, braided,embroidered, tailored fiber placement, deposition formed, film, sheet,cast, extruded, molded, expanded, reductions-formed, 3-D printed, andthe like material, as previously described.

The scrim 400 may be formed from synthetic and/or organic materials,such as polypeptide-based materials, cellulose-based materials,protein-based materials, aramids, glass, minerals, carbon, metallicand/or polymers, for example. As provided throughout, any materialand/or formation technique may be implemented as contemplated herein inregard to other scrims.

FIG. 4B depicts a cross-sectional view along cut line 4B of FIG. 4A, inaccordance with aspects hereof. The relative position of the heel end408 of the scrim and the heel end engineered elements 404 isillustrated.

FIG. 5A depicts a second cut fiber layer 500 comprised of a secondplurality of fibers 502 overlaying the assembly depicted in FIG. 4A, inaccordance with aspects hereof. The second cut fiber layer 500 may besimilar or different to the cut fiber layer 300 of FIG. 3A. For example,different fiber characteristics may be associated with the secondplurality of fibers 502 than the plurality of fibers 302 (e.g., thesecond plurality of fibers 502 may have a melting temperature (or asoftening temperature or a decomposition temperature) that is lower thana melting temperature (or a softening temperature or a decompositiontemperature) of the plurality of fibers 302). While the second cut fiberlayer 500 is depicted, it is contemplated that a single fiber layer beused in exemplary aspects to form a fiber-bound engineered material. Aswill be described in greater detail hereinafter, while the second cutfiber layer 500 is depicted as overlaying the entirety of the cut fiberlayer 300, it is contemplated that only a portion of the cut fiber layer300 may have a corresponding second cut fiber layer 500. Instead two ormore different fiber layers may be positioned to correspond with the cutfiber layer 300 to provide engineered characteristics to the fiber-boundengineered component by way of the alternative fiber layers andpositions of the various fiber layers.

FIG. 5B depicts a cross-sectional view along cut line 5B of FIG. 5A, inaccordance with aspects hereof. The relative position of the heel end408 of the scrim 400 and the heel end engineered elements 404 isillustrated.

FIG. 6A depicts the assembly of FIG. 5A subsequent to entanglement, inaccordance with aspects hereof. Entanglement causes an intermixing andmechanical engagement between the plurality of fibers 302 and the secondplurality of fibers 502. As previously described, the entanglement maybe achieved by a variety of mechanisms, such as needle entanglement(e.g., barbed or structured needle entanglement) or fluid entanglement(e.g., hydroentanglement). It is also contemplated that one or moreportions of the scrim 400 (as best seen in FIG. 6B) also may beentangled with one or more of the plurality of fibers 302 and the secondplurality of fibers 502.

FIG. 6B depicts a cross-sectional view of the assembly of FIG. 6A alongcut line 6B, in accordance with aspects hereof. As depicted, theplurality of fibers 302 and the second plurality of fibers 502 are notconfined to their respective fiber layers. Instead the entanglement hasmoved one or more fibers from each fiber layer into the alternativefiber layer to cause the entanglement and resulting binding to occur.Entanglement results in a consolidation of fibers. The consolidation offibers may be fibers from different fiber layers and/or scrim(s) into acohesive hybrid material that is a complex composite. As a result, thescrim 400 is fiber-bound and a fiber-bound engineered material is formedthat can be used to form an article (e.g., a shoe upper) with minimaladditional processing (e.g., cutting, sewing, and/or gluing).

The scrim 400 may be removed from the entangled fiber layers at thescrim 400 perimeter with the fibers entangled around and/or through thescrim 400. Depending on the various fibers forming the now-entangledfiber layers, waste from the removal process may be recycled. Forexample, if the plurality of fibers 302 and the second plurality offibers 502 have similar compositions, they may be recycled to formanother fiber layer. The ease of recycling fibers may drivemanufacturing efficiencies, in some examples.

It is contemplated that the resulting fiber-bound engineered materialfrom FIG. 6A subsequently may be formed into a shoe. For example, theassembly resulting from FIG. 6A may be joined at the heel and along thetoe. The joined portions subsequently may be placed on a cobbler's lastwhere underfoot portions may be joined to form a receiving cavity intowhich a foot eventually may be received. Additionally, one or moreprocesses may be implemented at any point, such as prior to removing theassembly from the excess fibers, subsequent to lasting, subsequent toclosure, and the like. The processes may include, by way of example andnot limitation, customizing to order, preparing for market byapplication of energy (e.g., thermal, light, radio wave, sonic, plasma,E beam, or vibrational energy), application of liquid chemistries,cutting, sewing, welding, pressing, heating, expanding, shrinking,printing, dipping, spraying, rolling, perforating, filling, emptying,painting, and/or applying a sole.

FIGS. 7A through 10C illustrate exemplary fiber layer constructions forforming a fiber-bound engineered material, in accordance with aspectshereof. FIG. 7A depicts a first fiber layer 700, a perimeter 702 of ashoe upper, and a second fiber layer 704, in accordance with aspectshereof. As used throughout, unless specifically indicated to thecontrary, the first fiber layer 700 and any other fiber layer (e.g., thesecond fiber layer 704) may be comprised of any fiber or combination offibers. As previously described, the fibers may be organic (e.g., wool,cotton, protein-based, or cellulose-based), synthetic (e.g., polymer oraramids), and/or engineered (e.g., carbon fiber, or glass).Additionally, the first fiber layer 700 and any other fiber layer (e.g.,the second fiber layer 704) described herein, unless specificallyindicated to the contrary, may be comprised of additional materials. Forexample, the additional materials may include, by way of example only,binders, colorants, reactive chemistries, fillers, primers, foamingmaterials, particles, powders, and the like. As provided herein, anymaterial listed throughout in connection with a fiber is contemplated.

The upper perimeter 702 may represent a distinct material, such as ascrim, and/or it may represent a perimeter defining a portion to beremoved from the assembly. In the latter, the upper perimeter 702 may bemerely representative for illustration purposes and to provide contextto the figure (e.g., the upper perimeter 702 may not be a physicaldemarcation that is visible) or the upper perimeter 702 may be a visibleindication/marking (and/or may include one or more visible markings forsizing, alignment and/or registration). In the former, where the upperperimeter 702 is a distinct material, it is contemplated that specificaspects (e.g., engineered materials) have been omitted for illustrationpurposes. However, it is contemplated that the upper perimeter 702, whena distinct material, may be comprised of one or more elements providedherein. Additionally, for aspects where the upper perimeter 702 is adistinct material, like other scrims described herein, the upperperimeter 702 may be formed from a variety of techniques (e.g., knit,woven, nonwoven, braided, embroidered, tailored fiber placement,deposition-formed, reductions-formed, cast, extruded, expanded,3D-printed, or film techniques) and it may be formed from a variety ofmaterials or combinations of materials. Additional upper perimeters willbe depicted throughout this application in a generic manner similar toupper perimeter 702, but it is understood that they too are merelydepicted in a simplified manner for illustration purposes and the abovedescription of the upper perimeter 702 is equally applicable.

FIG. 7B depicts an upper formed from the assembly of FIG. 7A, inaccordance with aspects hereof. Specifically, the first fiber layer 700forms a toe end portion and part of a midfoot portion. The second fiberlayer 704 forms a heel portion and a part of the midfoot portion. Inthis example, two concepts are explored and depicted.

First, it is contemplated that a single fiber layer may be used to forma portion of the article. For example, if the upper perimeter 702 is ascrim, the first fiber layer 700 may entangle with the upper perimeter702 and/or the first fiber layer 700 may entrap portions of the upperperimeter 702 as the first fiber layer 700 self-entangles. In thisexample, the scrim may be on an interior or exterior surface relative tothe single fiber layer. Depending on the purpose of the scrim, theinterior or exterior selection may be adjusted. For example, if thescrim provides structural integrity but is not as desirable from ahand-feel perspective relative to the fiber layer, the scrim may bepositioned on the exterior surface of the fiber layer. Alternatively, ifthe scrim material has better moisture movement characteristics relativeto the fiber layer, the scrim may be positioned on the interior surfaceof the fiber layer to be more effectively positioned proximate awearer's body, for example. Therefore, while the upper perimeter 702 isdepicted on an exterior surface of the formed article in FIG. 7B,alternative positions also are contemplated.

The second aspect explored in FIGS. 7A and 7B is the generation of anengineered material by layering of fiber layers. The layering of fiberlayers, as will be explored throughout, may be effective to impartengineered characteristics to a fiber-bound material. For example, theadditional fiber layers forming strata of an assembly may be comprisedof varied materials, in varied relative orientations, and/or in specificrelative locations, to achieve an intended characteristic at an intendedrelative location that is not uniform across the assembly. For example,the second fiber layer 704 may comprise a composition having a melttemperature or softening temperature that is below a melt temperature(or a softening temperature or a decomposition temperature) of the firstfiber layer 700. Therefore, energy may be applied to the assembly inFIG. 7B to melt (or at least initiate a state change of the composition)causing flow and/or bonding of the entangled fibers at the location ofthe second fiber layer 704. This alteration in state may provideincreased resilience, rigidity, moisture protection, visualcharacteristics (e.g., converting the second fiber layer to transparentor translucent), and/or the like in the portion of the articleincorporating the second fiber layer 704, in this example.

FIG. 8A depicts a first fiber layer 800, a perimeter 802 of a shoeupper, a second fiber layer 804, and a third fiber layer 806, inaccordance with aspects hereof. As previously described, the elementsdepicted in FIG. 8A are merely exemplary in nature and are not limiting.It is understood that any of the elements may be formed from a varietyof techniques and materials, as previously described in connection withFIG. 7A.

FIG. 8B depicts an upper component formed from the assembly of FIG. 8A,in accordance with aspects hereof. The layering of fiber layers isfurther emphasized in this example where the first fiber layer 800 formsa toe portion, the second fiber layer 804 forms a heel portion exteriorsurface, and the third fiber layer 806 forms a midfoot portion exteriorsurface. However, as depicted in FIG. 8C, a cross-sectional view alongcut line 8C of FIG. 8A, the assembly includes overlapping layers thatform a compound construction that has a tapered profile. A taperedprofile may provide a transition or gradation from a first region to asecond region. For example, the heel portion is comprised of the firstfiber layer 800, the upper perimeter 802 (e.g., a scrim in thisexample), the second fiber layer 804, and the third fiber layer 806. Asalso depicted in FIG. 8C, the various fiber layers are entangled forminga bonded assembly. For example, fibers from the first fiber layer 800extend into (and potentially through) the third fiber layer 806 forminga bond between the first fiber layer 800 and the third fiber layer 806.Similarly, fibers from the third fiber layer 806 extend into andentangle with fibers of the first fiber layer 800. Fibers from the firstfiber layer 800 also may extend into the second fiber layer 804. In someexamples, entanglement through multiple layers may occur depending onentanglement characteristics (e.g., availability and freedom of fibersto move, technique, duration, and/or pressure) and fiber characteristics(e.g., longitudinal length, longitudinal shape, traverse size, traverseshape, fiber length, strength, and bending modulus). The reciprocal mayalso be true. Fibers forming the second fiber layer 804 may extend into(and potentially through) the third fiber layer 806 to form afiber-bound assembly. The upper perimeter 802 may be entangled (asdepicted) with one or more fibers of the different fiber layers 800,804, 806. For example, if the upper perimeter 802 is formed from afiber-based structure, the fibers of the upper perimeter 802 and thefibers of the fiber layers 800, 804, 806 may interact to entangle andbond. Additionally or alternatively, the upper perimeter 802 may beencased by the fibers of the various fiber layers 800, 804, 806. Forexample, if the upper perimeter 802 is formed from an entanglementimpervious material (e.g., a polymer sheet with hydroentanglement), thefiber layers 800, 804, 806 may entangle around, but not through, theupper perimeter 802, in an exemplary aspect.

FIG. 9A depicts an alternative multi-fiber layer assembly, in accordancewith aspects hereof. A first fiber layer 900 is overlaid with a secondfiber layer 902 and a third fiber layer 904 to form an assembly. In thisexample, the second fiber layer 902 and the third fiber layer 904 arecoplanar and non-overlapping. Therefore, as depicted in FIG. 9B,illustrating an article formed from the assembly of FIG. 9A, a medialside may be formed from the second fiber layer 902 and a lateral sidemay be formed from the third fiber layer 904. As such, it iscontemplated that a first portion of a formed article may be engineeredin a first manner with a first fiber construction and a second portionof the formed article may be engineered in a second manner with a secondfiber construction such that the first and second fiber constructions donot interact (other than at a boundary there between, if one exists).While the fiber placement of FIG. 9A depicts a midline split between thesecond fiber layer 902 and the third fiber layer 904, it is contemplatedthat a split may occur in any location, orientation (e.g., traverse orbiased), and/or shape (e.g., organic shape, linear shape, or an islandnot sharing a boundary with neighboring coplanar materials), and thelike. As can be appreciated, different portions of an article may havedifferent functional needs. For example, an article of footwear may bedesigned to have variability in medial and lateral portions thereof torespond to greater sheer forces experienced by a lateral portion duringa cutting movement.

FIG. 10A depicts another co-planar fiber assembly, in accordance withaspects hereof. A first fiber layer 1000 has a plurality of fiber layersoverlaying. As such, the first fiber layer 1000 may be a carrier fiberlayer onto which engineered aspects are formed. In aspects, it iscontemplated that a carrier fiber layer may be formed from a materialhaving relatively neutral characteristics that would impart minimalengineered qualities to the article as a whole when formed. In otheraspects, the carrier fiber layer is contemplated to be a relativelyinexpensive material, such that it can be formed as a rolled good foruse in a continuous manufacturing process, in an exemplary aspect.Additionally, it is contemplated that a carrier fiber layer may beformed from a material that is able to be recycled. Further yet, it iscontemplated that a carrier fiber layer may be formed from acharacteristics-appropriate material. For example, an article offootwear may be formed such that the carrier material is a sock liner,underfoot portion, and/or interior surface of an article of footwear. Inthis example, the carrier fiber layer may be formed from a soft,non-abrasive fiber composition that has a higher abrasion resistance, ahigher pilling resistance, or higher melt, softening, or decompositiontemperature than typically experienced during manufacturing or wear, forexample. Stated differently, it is contemplated that fiber-boundengineered materials may include an underfoot portion for an article offootwear. The fiber-bound engineered materials also may have an interiorsurface that serves as a sockliner, which allows for omission of atypical additional material layer to serve as a sock liner. Therefore,the fiber-bound engineered material can form a lighter, moreform-fitting shoe than traditional materials.

A second fiber layer 1002, a third fiber layer 1004, and a fourth fiberlayer 1006 are all depicted as coplanar fiber layers overlaying an upperperimeter. In this exemplary arrangement, a heel end on both medial andlateral sides is formed with the second fiber layer, as depicted inFIGS. 10B and 10C. The medial side, inclusive of the toe portion, isformed from the third fiber layer 1004 (as depicted in FIG. 10C). Thelateral side, inclusive of the toe portion, is formed from the fourthfiber layer 1006 (as depicted in FIG. 10B). As such, it is demonstratedin FIGS. 10A through 10C that a variety of coplanar arrangements may beimplemented to achieve an engineered material through manipulation ofthe fiber layer(s).

FIGS. 11A through 14B provide examples of multiple scrims and relativeposition and/or characteristic differences, in accordance with aspectshereof. Specifically, FIGS. 11A through 14B depict a variety ofconfigurations based on the interaction of fiber layer(s) with one ormore scrims, material selection and resulting entanglement and/orentrapment/encasement of the scrim(s), and relative position of multiplescrims with respect to one another.

FIG. 11A depicts a first fiber layer 1100 comprised of a plurality offibers 1102, in accordance with aspects hereof. As previously provided,it is contemplated that the first fiber layer 1100 (or any fiber layer,unless explicitly indicated to the contrary) may be formed from anycombination of fibers. The first fiber layer 1100 may be uniform orvariable in fiber composition. As such, it is contemplated that thefirst fiber layer 1100 may be engineered or stock in exemplary aspects.A first scrim 1104 and a second scrim 1106 also are depicted in FIG.11A. The first scrim 1104 and the second scrim 1106 may be any materialor construction (e.g., knit, woven, nonwoven, braided, tailored fiberplacement, embroidered, deposition-formed, reductions-formed, molded,cast, expanded, 3D-printed, sheet, film, etc.); however, in aspects,they are contemplated as a textile-like material as depicted. Aspreviously provided, the exemplary scrims depicted in the figures,unless indicated to the contrary, may be comprised of any materialcomposition, formation technique, size, shape, and/or orientation.

FIG. 11B depicts a cross-sectional view along cutline 11B of FIG. 11A,in accordance with aspects hereof. As depicted, a plurality of fibers1102 extends through and entangles with the first scrim 1104 and secondscrim 1106. In this example, the first fiber layer 1100 serves as thesole fiber binder of the first scrim 1104 and the second scrim 1106. Forexample, no active binder other than the fibers 1102 may be used tocouple one or more of the scrims together or to the fiber layer 1100.For example, adhesives, mechanical fasteners, or the like may beomitted. Omission of these alternative binders prevents the binders frominserting characteristics or limitations into the assembly. For example,an adhesive may limit stretch, increase rigidity, reduce airpermeability, and the like, in one or more portions for which thatcharacteristic is not intended. Further, the non-fiber binding optionsmay increase thickness, weight, cost, and/or manufacturing processes.Therefore, aspects herein contemplate omitting alternative bindersaltogether, or limiting their implementation in other aspects. Fiberbinding is an effective binding solution that works to form anengineered material. It is also contemplated that the fiber layer may beformed with fibers of a material (e.g., a fusible material) that maybond with scrim materials through means other than entanglement. Forexample, the fiber layer may be formed having one or more fusible fibersfrom a first fusible material and a scrim may be formed to include atleast a portion having the first fusible material as well. Subsequent to(or prior to) entanglement, the first fusible material may be activated(e.g., energy may be applied thereto) causing a bond between the fiberlayer and the scrim to be enhanced relative to that achieved from mereentanglement alone, in an exemplary aspect.

The first scrim 1104 is overlapped by a portion of the second scrim1106. This provides an example of how multiple scrims (engineered orstock) may be combined and bound in relative position by fiberentanglement. Therefore, if a first scrim has a first characteristic anda second scrim has a second characteristic, the combination of the firstcharacteristic and the second characteristic may be achieved with fiberbinding to result in an engineered textile. Depending on an entanglementtechnique implemented, the entanglement may occur from a first side onlyor from both sides of the assembly. In this example, since a fiber layeris only on a single side, an entanglement process that is capable ofbringing fibers through the scrims may be leveraged. An example mayinclude barbed-needle entanglement where barbs of the needle areeffective to push and pull on fibers to encourage entanglement.Additionally, fluid entanglement from at least a back side of theassembly is contemplated. Fluid enanglement from both the back and afront sides of the assembly is effective to achieve a different (e.g., apotentially stronger) binding between the scrims as the fibers areforced both forwards and backwards.

FIG. 12A depicts a fiber layer 1200 comprised of a plurality of fibers1202, in accordance with aspects hereof. A first scrim 1204 and a secondscrim 1206 also are depicted. As best seen in the cross-sectional viewalong cutline 12B and represented in FIG. 12B, the first scrim 1204 andthe second scrim 1206 are encased within the fiber layer 1200. Theencasement can be achieved by starting with at least a first fiber layeron a first side of the scrims 1204, 1206 and at least a second fiberlayer on an opposite second side of the scrims 1204, 1206 and thenentangling the first and second fiber layers to result in the fiberlayer 1200. As depicted in FIG. 12B, one or more of the plurality offibers 1202 also extend through and entangle with the first scrim 1204and the second scrim 1206. The first scrim 1204 and the second scrim1206 are fiber-bound by at least a portion of the plurality of fibers1202 and form a fiber-bound engineered material where the scrims 1204,1206 are encased within the fibers.

FIG. 13A depicts a fiber layer 1300 comprised of a plurality of fibers1302, in accordance with aspects hereof. A first scrim 1304 and a secondscrim 1306 are encased within the fiber layer 1300 in a manner similarto FIGS. 12A and 12B. However, the first scrim 1304 and the second scrim1306 are formed from an impervious material. An impervious material is amaterial through which fibers do not extend as a result of theentanglement process. A substantially impervious material is a materialthat while entanglement occurs, the fiber bonds created are ofinsufficient strength to resist minor agitation. For purposesthroughout, impervious materials also may include substantiallyimpervious materials, unless indicated otherwise. Examples may includefilm or sheet-like materials.

As depicted in FIG. 13B, a cross-sectional view along cutline 13B ofFIG. 13A, the plurality of fibers 1302 do not extend through the firstscrim 1304 nor the second scrim 1306. In this example, the scrims aremaintained through perimeter entanglement between the plurality offibers 1302 and not through entanglement between the plurality of fibers1302 and the scrims 1304, 1306 themselves. Therefore, as will bedescribed hereinafter, if the fiber layer 1300 is manipulated (e.g.,slit) proximate one of the scrims, the scrim may be removed or dissolvedand a volume previous filled with the scrim will remain as a pocketwithin the fiber layer 1300. Therefore, use of an impervious materialallows for creation of voids or other cavities within a fiber layer, inan exemplary aspect. As will be described hereinafter with respect toentrapped scrims or components, an impervious material may allow forbinding while still allowing for movement within the formed fiber case.

FIG. 14A depicts a fiber layer 1400 with a plurality of fibers 1402, inaccordance with aspects hereof. A first scrim 1404 is formed from amaterial that can be entangled (e.g., a textile) and a second scrim 1406is formed from an impervious (relative to fibers) material (e.g., apolymer sheet or film). Further, for exemplary purposes, the first scrim1404 and the second scrim 1406 are non-overlapping scrims. As depictedin FIG. 14B, the first scrim 1404 and the second scrim 1406 are coplanarscrims, but it is contemplated that they may be offset in a Zdirectional placement (non-coplanar) in alternative aspects. Forexample, one or more fiber layers may be positioned between the scrimsin the Z-direction prior to entangling the fiber layers. In thisexample, the assembly would be comprised of multiple scrims that arenon-coplanar. In this example, it is further contemplated thatZ-directional offset scrims may overlap in whole or in part in the X orY directions.

Returning to FIG. 14B, the plurality of fibers 1402 pass through andentangle with the first scrim 1404. The plurality of fibers 1402 do not,however, pass through or entangle directly with the second scrim 1406.Instead, as previously described, the plurality of fibers 1402self-entangle and form a case that entraps (encases) the second scrim1406.

FIGS. 15 through 17 depict scrims having direction engineeringaccomplished through one or more engineering elements, such ashigh-tensile strength (e.g., low stretch) relative to an associatedfiber layer.

FIG. 15 depicts an article 1500 comprised of an article perimeter 1502and a first engineering element 1504. The first engineering element 1504may be (or may become through subsequent processing) a high tenacity,high tensile strength, low stretch material, such as a cord, wire,molded matrix, deposited matrix, filament, thread, roving, and the like.The measured characteristics (stretch, tenacity, and tensile strength)may be relative to an associated fiber layer serving as a fiber binderto the first engineering element 1504. The illustrated article perimeter1502 represents a shoe upper configuration. As with previousdescriptions herein, an article perimeter, such as the article perimeter1502, may exist visually on a fiber layer, in theory for illustrationpurposes, or as a physical element (e.g., as a scrim having that shape).A toe-to-heel direction is represented by arrow 1508. A biasedmedial-to-lateral direction is represented by arrow 1506. With thearrangement of the first engineering element 1504, a stretch is limitedin the direction of arrow 1506 as that is substantially parallel with adirection of placement of the first engineering element 1504. However, astretch in the direction of arrow 1508 is minimally if at all affectedby the first engineering element 1504. As such, article 1500demonstrates how orientation of engineering materials serving as a scrimcan impart engineered characteristics to a fiber layer to be afiber-bound engineered material. In this example, the first engineeringelement 1504 may be a tailored fiber placement, which may have a lockingstitch, such as an embroidery stitch, maintaining the fiber in aspecified location of an underlying material. The locking stitch may beformed from any material, even a fugitive material that is laterdissolved. Alternatively, it is contemplated that a locking stitch witha discrete thread is omitted. Instead, an entanglement process may beused as the element (e.g., roving) is applied to an underlyingsubstrate, such as a scrim. For example, as the element is placed, oneor more barbed needles may entangle the element with a fiber layer.Other means of entanglement (e.g., fluid entanglement and/orstructured-needle entanglement) may be implemented.

FIG. 16 depicts an article 1600 comprised of an article perimeter 1602,a first engineering element 1604, and a second engineering element 1606.The first engineering element 1604 and the second engineering element1606 each may be (or may become through subsequent processing) a hightenacity, high tensile strength, low stretch material, such as a cord,wire, roving, and the like. The article perimeter 1602 represents a shoeupper configuration. The first engineering element 1604 limits stretchin a direction represented by an arrow 1608 and the second engineeringelement 1606 limits stretch in a direction represented by an arrow 1610.Further, following an entanglement processes, it is contemplated thatthe first engineering element 1604 and the second engineering element1606 work in summation as an intersection of the elements 1604, 1606form common points of bonding, in an exemplary aspect. Therefore, theresulting characteristics of the scrim formed by the first engineeringelement 1604 and the second engineering element 1606 may be differentthan if each of the engineering elements 1604, 1606 was to be measuredindividually.

FIG. 17 depicts an article 1700 comprised of an article perimeter 1702,a first engineering element 1704, a second engineering element 1706, anda third engineering element 1708. Each of the first engineering element1704, the second engineering element 1706, and the third engineeringelement 1708 may be (or may become through subsequent processing) a hightenacity, high tensile strength, low stretch material, such as a cord,wire, roving, and the like. The illustrated article perimeter 1702represents a shoe upper configuration. It is contemplated that theengineering elements 1704, 1706, 1708 may be the same, similar, ordifferent. The engineering elements 1704, 1706, 1708 may be different inmaterial, construction, size, and/or the like. As provided in FIG. 17,it is contemplated that a zonal configuration for the engineeringelements 1704, 1706, 1708 may be formed. For example, in a heel end ofthe article perimeter 1702, the third engineering element 1708 limitsstretch in the heel-to-toe direction of the article perimeter 1702. Whenconstructed into a three-dimensional shoe upper, the third engineeringelement 1708 is effective to limit stretch around a heel end in amedial-to-lateral direction. Therefore, FIG. 17 contemplates andexplores zonally placing engineering elements to achieve a variable(e.g., zonally applied) engineered characteristic. While depicted in theheel area, it is contemplated that one or more alternative or additionalzones may have an engineering element. Further, while the engineeringelements are described with respect to a limitation in stretch,additional (or alternative) characteristics also may be achieved byengineering elements. For example, an engineering element may be a foamelongated portion that is integrated to provide impact attenuation orother cushioning characteristics.

FIGS. 18A through 21B depict different upper configurations andpotential scrim positions, in accordance with aspects hereof. Whilecertain upper configurations are depicted with specific scrimplacements, it is contemplated that an upper configuration may becombined with the intended result of a depicted scrim. For example, ascrim configured to add engineering characteristics to a heel sectionmay be of a first shape for a first upper configuration and the scrimmay be of a different shape (or may be comprised of multiple scrims) fora different upper configuration. Therefore, a contemplation of alocation of a scrim allows for a translation between scrim shapes,sizes, and positions to be effective for a similar purpose onalternative upper configurations. Stated differently, discrete elementsdescribed and depicted herein demonstrate principles that may beimplemented and are not limiting. Instead, the principles provided areguiding to combinations that may be formed.

FIG. 18A depicts a planar upper 1800 having a base portion 1802 and ascrim 1804, in accordance with aspects hereof. A base portion may be afiber layer and/or a scrim. As provided herein, the base portion and thescrim(s) may be formed from a variety of materials (e.g., organic orsynthetic) with a variety of techniques (e.g., knit, woven, nonwoven,embroidered, tailored fiber placement, deposition-formed,reductions-formed, expanded, 3D-printed, molded, or extruded). The scrim1804 provides engineering characteristics to a midfoot region on both amedial and a lateral side extending around a throat portion toward asole coupling location, as seen in FIGS. 18B and 18C. In this example, acontinuous scrim extends across multiple portions of the article and maybe effective for a variety of engineering characteristics. A continuousscrim is an unbroken whole that is without interruption, in an exemplaryaspect. For example, the scrim 1804 may be effective to transfer a laceload from the throat region toward the sole more effectively than thebase portion 1802 alone. For example, the scrim 1804 may have a lowermodulus of elasticity than the base portion 1802.

In another example, the scrim 1804 (or any scrim provided herein) may beformed to have a plurality of openings, such as a knit large mesh. Inthis example, when a fiber layer is entangled about the plurality ofopenings, a texture is created. Depending on a size of the apertures andthe characteristics of the fibers, the fibers may not obscure theapertures and instead entangle around the positive portion of the scrimand leave the negative space substantially negative. Therefore, in theexample of FIGS. 18A through 18C, a high air permeable portion may beformed in the location of the scrim 1804. In this regard, the scrim maybe effective to form a macro texture that is exposed, in part, throughan entanglement process. This concept may be applied to any scrimprovided herein.

FIG. 19A depicts a planar upper 1900 having a base portion 1902, a firstscrim 1904, a second scrim 1906, a third scrim 1908, and a fourth scrim1910, in accordance with aspects hereof. While a specific combination ofscrims is depicted and will be described, it is understood with FIG. 19Aand the other FIGS. that one or more depicted elements may be omitted oraltered. Further, it is contemplated that one or more scrims may beadded.

The first scrim 1904 is on a lateral portion of a heel region of theplanar upper 1900 when in its dimensionally formed state (see FIG. 19B).The second scrim 1906 is on a medial portion of the heel region. Thethird scrim 1908 forms around a throat on the medial and lateral sides,as well as across a vamp portion. The fourth scrim 1910 extends from themedial and lateral sides across a toe box. A fifth scrim 1912 isdepicted in the under-foot region. The fifth scrim 1912 may providestability, cushion, fit, and/or the like. The fifth scrim 1912, whiledepicted as filling a substantial portion of the underfoot region, mayinstead be concentrated at a heel region, arch region, forefoot region,or toe region, in aspects hereof. The fifth scrim 1912 may provideunderfoot engineering, such as arch support, cushioning, foot alignment,and the like. Each of the scrims 1904, 1906, 1908, 1910, 1912 may beformed from different materials, formed utilizing different techniques,and/or have different characteristics.

For example, the first scrim 1904 and the second scrim 1906 may serve toreinforce the heel region and to provide additional rigidity.Additionally or alternatively, the first scrim 1904 and the second scrim1906 may serve as cushioning in the heel region, such as through a loftyor foamed material forming the respective scrims. The third scrim 1908may be formed from a material that has a greater tear resistance thanthe base portion 1902. The greater tear resistance is incorporatedaround lace apertures that can expose the throat portion to concentratedtensile forces from securing the article to a wearer. The fourth scrim1910 may be formed from a material and/or technique that providesabrasion resistance that is greater than the base portion 1902. A shoemay experience scuffs and scrapes at the leading toe edge that are notexperienced as commonly elsewhere on the shoe. As a result, the fourthscrim 1910 is effective to engineer the abrasion resistancecharacteristic into the planar upper 1900.

FIG. 19B depicts the planar upper 1900 of FIG. 19A in a dimensionallyformed state, in accordance with aspects hereof. FIG. 19B includes atongue portion not depicted in FIG. 19A; however, it is contemplatedthat a tongue portion may be formed as part of an upper pattern or itmay be formed separately and attached subsequently.

FIG. 20A depicts a planar upper 2000 having a base portion 2002 and ascrim 2004, in accordance with aspects hereof. While depicted as asingle scrim, the scrim 2004 in actuality may be formed from two or moreportions. The scrim 2004 is formed along a coupling perimeter of theplanar upper 2000. A perimeter scrim may extend along any perimeter,such as an ankle collar, forefoot opening, and the like. A perimeterscrim may be continuous and/or discrete such that a bonding perimeterand/or a finished edge perimeter may be a common or discrete scrim.

The planar upper 2000 may be lasted and a strobel sock and/or board(sometimes referred to as a lasting board) may be joined with the planarupper 2000 to form a dimensional shoe. The joining may be accomplishedthrough stitching (e.g., strobel stitch), adhesives, and/or othercoupling techniques. The joining at a perimeter can expose the perimeterto concentrated tensile forces that may subject the upper material totearing, ripping, or otherwise deforming when the base portion 2002alone is used. As such, the scrim 2004 is effective to resist thenegative results of joining along a perimeter, such as addingdimensional stability, greater tear resistance, and the like. The scrim2004 may extend from the perimeter of the base portion 2002 to a pointinside a biteline to prevent exposure of the scrim in a finishedarticle. A biteline is a line formed at a transition between an upperand a sole.

FIG. 20B shows a bottom view of the planar upper 2002 having a strobelboard joined at the perimeter. It is understood that a scrim may serveas a joining reinforcement alone or in combination with one or moreother characteristics. For example, a discrete scrim may serve as ajoining reinforcement or a scrim may include a portion for serving as ajoining reinforcement.

FIG. 21A depicts a planar upper 2100 having a base portion 2102 and ascrim 2104, in accordance with aspects hereof. The scrim 2104 extendsacross a heel portion from both a medial side and a lateral side. Thescrim 2104 also extends toward the throat to a first lace aperture onboth of the medial and lateral sides in this example. The scrim 2104 mayprovide a transfer of tensile forces from the lace apertures heelwardlytoward a sole portion to aid in securing the shoe to a wearer. The scrim2104 also may provide rigidity and/or cushioning in the heel region. Asprovided herein, a scrim may provide one or more engineeredcharacteristics provided herein. FIG. 21B depicts the planar upper 2100in a formed dimensional configuration, in accordance with aspectshereof. FIG. 21B depicts a tongue portion not originally depicted inFIG. 21A. However, it is contemplated that the tongue portion may beformed as part of the planar upper 2100 of FIG. 21A or it may be formedseparately and incorporated into the article of footwear.

Element Scrims

As previously set forth, a scrim is an element maintained in a relativeposition by one or more fiber layers as a fiber-bound element. FIGS. 22Athrough 25D explore element scrims, in accordance with aspects hereof.An element scrim, as provided above, may include one or more elementstraditionally applied to a textile with a different coupling mechanismand the elements may have a functional purpose beyond the textile.Non-limiting examples of elements may include snaps, buttons, zippers,hook and loop structures, tubing, rings, grommets, electrical sensors,electrical transmission elements, fiber optics, bladders, tread/tractionelements, and the like. Element scrims also may include elements thatform a raised surface relief that provides a visually, cognitively,and/or tactilely perceived presence and/or absence of an entrapped orencased scrim. Element scrims that form a raised surface relief may nothave a functional purpose beyond the textile and may be provided inwhole or in part for the visual appearance they provide.

FIGS. 22A through 22E depict exemplary elements in various views andstates of entanglement. FIG. 22A depicts a plan view of a collection ofelements 2200, in accordance with aspects herein. The collection ofelements 2200 includes an impervious generic element 2210, a secondimpervious generic element 2212, a snap with a flange 2214, a snap witha first entanglement flange 2216, a snap with a second entanglementflange 2218, an electrical element with an entanglement flange 2220, afirst solid channel 2222, a second solid channel 2224, a firstdeformable channel 2226, a first hollow channel 2228, a second hollowchannel 2230, and a D-ring 2232. It is understood this collection ofelements 2200 is exemplary in nature and is not limiting.

Some of the elements may be merely encased within a fiber layer andothers may be entangled with the fibers. As will be explained in greaterdetail below, the mere encasement may allow movement (e.g., rotation) ofthe element within the defined encasement volume. Additionally, as alsowill be explained in greater detail hereinafter, the merely encasedelements easily may be removed from the entangled fiber layer to createa volume (e.g., a pocket, a channel, a window, or an opening) whereinthe encased element was positioned during entanglement and prior toremoval. The entangled elements may be securely fiber bound to at leasta fiber layer (and also potentially to one or more scrims) to preventmovement of the element, such as rotational movement. The elements maybe formed from any material or combination of materials, such as,without limitation, a polymer, metal, and/or organic material. Theelements may be formed from any technique, such as molded,deposition-formed, reductions-formed, extruded, and the like. Theelements may have any size, shape, or configuration.

The impervious generic element 2210 may be any element that is encasedwithin a fiber layer. As best seen in FIG. 22E, a portion of an encasingfiber layer may be removed to expose the impervious generic element2210. This is possible, in part, as the removed fibers from the fiberlayer are not entangled with the impervious generic element 2210.Therefore, the impervious generic element 2210 may provide a mask,window, or other feature as will be described hereinafter. In aspects, aportion of the fibers forming the encasing fiber layer may be manuallyor forcibly parted or separated to expose a portion of the imperviousgeneric element 2210. For instance, the impervious generic element 2210may include a peaked or raised portion or other suitable protuberancethat, upon forcible or manual separation of fibers, may be exposed.

The second impervious generic element 2212 is similar to the imperviousgeneric element 2210, but as seen best in FIG. 22E, an aperture isformed through the fiber layer(s) and the second impervious genericelement 2212 post-entanglement. Therefore, the second impervious genericelement 2212 provides an example of post-processing that may beperformed on a scrim to further engineer a fiber-bound engineeredmaterial. In aspects hereof, the second impervious generic element 2212may provide a reinforcement, a lace aperture, or other purpose. Theaperture formed through the second impervious generic element 2212 andthe fiber layer(s) may be formed by, without limitation, a punch, adrill, a CNC machine, a laser, a water jet, cutting, slitting,dissolving, and the like.

The snap with a flange 2214, while called a “snap” may be a grommet orother ring-shaped element. The snap with a flange 2214 may be formedfrom an impervious material as depicted in FIG. 22C such that fibersfrom the fiber layers do not entangle with the snap with a flange 2214,but instead the fibers entangle with each other, fiber binding the snapwith a flange 2214 in a volume to encase the snap with a flange 2214. Asthe snap with a flange 2214 has a symmetrical shape within the volumeencasing the snap with a flange 2214 and the snap with a flange 2214does not include entanglement structures, the snap with a flange 2214may be free to rotate within the volume while still being secured to thefiber layer. A reciprocal snap element intended to mechanically engagethe snap with a flange 2214 is also contemplated, but not depicted.

It is contemplated that a scrim, such as an element scrim, may besufficiently encased within a fiber-bound layer to at least temporarilyposition and maintain the scrim. A subsequent operation, such asapplication of pressure, heat, adhesive, and the like, may be used tofinally secure the entrapped scrim with the fiber layer. Stateddifferently, an entrapment and/or entanglement may be used as atemporary bonding process to maintain a position of a scrim and asubsequent process may be implemented to supplement the bonding tosecurely maintain the scrim relative to the fiber layer.

The snap with a first entanglement flange 2216 is similar to the snapwith a flange 2214, but the flange portion includes a plurality ofapertures through which fibers from the fiber layer(s) may extend. Thefibers that extend through the apertures of the flange may prevent therotational movement within a fiber volume provided by the snap with aflange 2214. Therefore, it is contemplated that an element may beadapted to be merely encased or entangled with fibers through one ormore structural changes, such as an aperture through a flange in thisexample.

The snap with the second entanglement flange 2218 provides analternative flange concept that may provide a different entanglementcharacteristic than the snap with a first entanglement flange 2216. Thesnap with a first entanglement flange 2216 and the snap with a secondentanglement flange 2218 provide examples of how an entanglementcharacteristic with an element may be adjusted through a structuralchange of the element. For example, instead of apertures extendingthrough an existing structure, the structure itself may be altered toenhance entanglement characteristics, as depicted by the snap with asecond entanglement flange 2218. As such, it is contemplated that anentanglement structure may be co-produced or post-produced from similaror dissimilar materials to the scrim portion to which the entanglementstructure is attached.

The electrical element with an entanglement flange 2220 represents anyelectrical component (e.g., sensor, light, integrated circuit, battery,or antenna) that may be fiber bound to an engineered material. Whiledepicted with an entanglement flange, it is contemplated that theelectrical elements may be merely encased and not entangled in someaspects. It is contemplated that one or more electrical conductors mayextend to the electrical element with an entanglement flange 2220 (orany electrical element secured with fiber binding). The electricalconductors may be part of a scrim or independent elements that also arefiber bound by a fiber layer. For example, an electrical harness havinga selection of components electrically coupled may be inserted as one ormore scrims that are entangled with one or more fiber layers.

The first solid channel 2222 is similar in concept to the imperviousgeneric element 2210; however, the first solid channel 2222 iscontemplated to have an extended longitudinal length relative to atraverse cross-section measurement (e.g., a diameter). The first solidchannel 2222 may represent a fiber optic, an electrically-conductiveelement or another impervious element.

The second solid channel 2224 is similar to the first solid channel2222; however, as can be seen in FIG. 22E, the second solid channel 2224may be removed to form a channel within the entangled fiber layer in thevolume previously filled by the second solid channel 2224. Because thesecond solid channel 2224 is impervious, fibers do not entangletherewith and the second solid channel 2224 may be removed withoutsignificant damage to the entangled fiber layer.

The first deformable channel 2226 is contemplated to have an extendedlongitudinal length relative to a traverse cross-section measurement(e.g., a diameter) with a resilience that allows for temporary orpermanent deformation in the traverse cross-section. The deformation isdepicted in FIG. 22C. It is contemplated that the first deformablechannel 2226 may provide an impact-attenuating ability or othercushioning function, in exemplary aspects.

The first hollow channel 2228 may be a tube-like structure having anytraverse cross-sectional shape (e.g., round, ovoid, triangular,rectilinear, lobed, dogbone, or hollow). A tube-like structure may beeffective to conduct a fluid, such as a liquid or a gas, or to maintain,foamable materials, flowable materials, expandable materials, orstate-changing materials. Additionally a tube-like structure may serveas a conduit through which elements (e.g., fiber optics, micro fibers,or electrical components) may pass subsequent to entanglement. Forexample, elements that may not be suitable to be processed withentanglement (e.g., due to increased risk of breakage) still may beintegrated into a fiber-bound engineered material by using the firsthollow channel 2228 as a conduit.

The second hollow channel 2230 may be like the first hollow channel2228; however, it may be relatively non-deformable in a cross-section,as seen in FIG. 22C.

The D-ring 2232 represents an element that may be encased but,leveraging rotational movement, may be repositioned, in part, from theexterior of the fiber layer, as seen in FIG. 22D. For example, theentire D-ring 2232 may be encased in the fiber layer, but a mask ortrimming operation may free the curved portion leaving the linearportion encased. Subsequent to freeing the curved portion of the D-ring2232, the curved portion may rotate about an axis defined by alongitudinal direction of the linear portion still encased. While a ‘D’ring is depicted, it is contemplated that any ring or clasp may befiber-bound. In an exemplary aspect, the clasp or ring may have a linearportion that can freely rotate while being encased. However, it iscontemplated that a rotation may not be leveraged and a portion of fiberencasing the ring or clasp may be trimmed to allow at least a portion ofthe ring or clasp to be accessible beyond the fiber layer. Rotation maybe inhibited or encouraged through structural design (e.g.,non-symmetrical design or inclusion of entanglement structures) of theencased element and/or post-processing (e.g., application of energy,heat, pressure, or adhesive).

FIG. 22B depicts a cross-sectional view of the elements from FIG. 22Ahaving a first fiber layer 2234 above and a second fiber layer 2236below, in accordance with aspects hereof. While two fiber layers aredepicted, it is contemplated that some elements may be sufficientlyentangled with a single fiber layer. Those elements merely encased,however, may benefit from at least a second fiber layer to form anencasing fiber structure to be entangled, in an exemplary aspect. Thecross-section also illustrates fibers entangled with elements, such asthrough the entanglement flanges of snaps 2216 and 2218.

FIG. 22C depicts the cross-sectional view of FIG. 22B subsequent toentangling the first fiber layer 2234 and the second fiber layer 2236,in accordance with aspects hereof. The entanglement fiber binds theelements. The entanglement results in the elements being at leastpartially encased and/or entangled with the fibers.

FIG. 22D depicts a plan view of some elements from FIG. 22C subsequentto having a trimming operation performed thereon, in accordance withaspects hereof. FIG. 22E depicts a cross-section along cut line 22E ofFIG. 22D, in accordance with aspects hereof. As can be seen in the FIGS.22D and 22E, a post-entanglement trimming operation can remove portionsof fibers to expose one or more portions of the elements encased thereinand/or entangled therewith. The trimming operation also may extract aportion of the element itself, such as for the second impervious genericelement 2212. Also, it is contemplated that a post-entanglement elementmay be exposed, in part, to permit access, such as an element 2238.Further, an element may be extracted altogether leaving a fiber cavityin a void that was formed during entanglement around an element, asdepicted by 2240.

It is contemplated that a fiber cavity may be filled with one or morematerials. For example, a foamable material and/or a flowable material,such as a pellet or powder, may be inserted into the fiber cavity. Thecavity may be sealed through further entanglement or other closure meanswith the foamable and/or flowable material contained therein. Thefoamable material may be foamed (e.g., triggered with heat or othercatalyst) such that the fiber cavity fills with the foamable material.Other materials also are contemplated, such as a curable material (e.g.,silicone) that may be inserted in a first state (e.g., liquid,dispersion, or paste) and form into another state (e.g., a resilientsolid). The channel provides a vessel to contain the added materials, inan exemplary aspect. Additionally, a fiber cavity may serve as a channelthrough which a draw string or other cinchable element may extend. It isfurther contemplated that a locking element (e.g., a cord lock) may befiber-bound in the material to maintain the draw string at a settension. Further yet, it is contemplated that a low-friction surfacecoating may be applied or formed along the fiber-formed cavity/volume.The low-friction surface coating may be low friction relative to anuntreated portion of the same fiber material. The low-frictioncharacteristic may be in threading elements through the fiber volume orfor moving items once within the fiber volume.

As previously set forth, fiber-encased elements include elements thatform a raised surface relief. The raised surface relief provides avisually, cognitively and/or tactilely perceived presence and/or absenceof entrapped scrims and scrim elements including transitions providing adistinctive signature “bound by fiber” appearance. One aspect of thesignature appearance is that it alludes to an alternative manufacturingtechnology due to the lack of obvious traditional construction orattachment mechanisms, such as stitching or fused sheet plastic polymerfilms. Examples may include, without limitation, scrims and fibers(e.g., molded parts, foams, support cables, fusible fiber bundles, andtextiles (such as those with openings)) having physical properties thatcreate perceivable differentiations such as pattern, texture, colordifferentiation, Z-dimensional differentiation, density and/or otherphysical characteristic where the variabilities are detectable. Inaspects, a scrim may be subjected to one or more or manufacturingprocesses (e.g., dyed, screen-printed, embroidered or the like) prior tofiber binding such that upon fiber binding, one or more visualproperties of the scrim may become visible on a surface of a resultantmanufactured article. For instance, a portion of a pre-processed scrimmay extend through the fibers (e.g., creating a color differentiation)and/or may be encased or entrapped by the fibers (e.g., creating araised surface relief of a desired shape or configuration).

FIG. 27 depicts an article of footwear 2700 formed utilizing a meshscrim and a scrim having a pattern embroidered thereon with a hightenacity thread (which may be of any color or reflectivity, as desired).When fiber-bound, the embroidered pattern 2710 is visible at the surfaceof the manufactured article. In the article of FIG. 27, a separatelyapplied skin layer 2712 also is applied on the surface of thefiber-bound article that will form the exterior-facing surface of theresultant manufactured article of footwear 2700.

Tactile features of fiber-bound encased elements in a shoe upper mayinclude soft, lightweight, compliant, permeable and non-plasticy,relative to the appearance, heaviness and less compliant feel ofelements traditionally bonded with adhesives or melt-bonded with sheetplastic polymer films.

The above phenomena may be observed or experienced where the entrappedelements have heightened visual, cognitive and/or tactile perceivabilitydue to the change in surrounding media such as is produced bytranslucency/transparency and/or textural cues created by fibers,additives, treatments, polymer encasements, shape transformation (suchas by bending or molding) and/or the addition of temporary or permanentlight emitting elements within or beyond the structure that providebacklighting to reveal the internal layering of, and/or transitionsbetween, entrapped scrim and fiber elements.

Turning now to FIG. 23A, depicted is a zipper 2300, in accordance withaspects hereof. The zipper 2300 is comprised of a first tape 2302 and asecond tape 2304. A first plurality of teeth 2306 is coupled with thefirst tape 2302. A second plurality of teeth 2308 is coupled with thesecond tape 2304. While not depicted, it is contemplated that the zipper2300 may be comprised of top stops, bottom stops, insert pin(s), boxpin(s), and/or a retaining box, as is traditional for a zipper. A slideris included to engage and/or disengage the first plurality of teeth 2306and the second plurality of teeth 2308. Optional apertures 2310 on thefirst tape 2302 and optional apertures 2312 on the second tape 2304 alsoare depicted. However, the apertures in connection with the tapes 2302,2304 are exemplary in nature. They may be of any size, shape, order,position, sequence, or the like. In an alternative aspect, each toothmay have an integrally formed or joined entanglement structure that mayallow for direct entanglement of a tooth without a tape-like structure.For example, each tooth (or a collection of teeth) may be formed (e.g.,molded) with one or more entanglement structures. Therefore, theentanglement process is an effective process to maintain a set positionof the one or more teeth with or without a supplemental tape.Additionally, in addition to or in the alternative of aperturesextending through the tape, the tape itself may be an entanglementstructure (e.g., a fiber-formed material susceptible to fiberentanglement).

In an exemplary aspect, the zipper 2300 is an element scrim that isfiber-bound to a fiber layer. Fibers of the fiber layer entangle withthe first tape 2302 and the second tape 2304. The entanglement with thetape(s) 2302, 2304 may occur by puncturing the tape(s), such as throughneedle entanglement (barbed-needle entanglement or structured-needleentanglement), or through a modified tape (or integral entanglementstructure) having one or more structures adapted to encourageentanglement. An example of entanglement structures includes theapertures 2310 and 2312. Alternative structures also are contemplated,such as non-linear edges on the tape (e.g., scalloped edges), slits,and/or flange portions, such as the flange elements depicted in FIG. 22Aon the snap with the second entanglement flange 2218.

In an exemplary aspect, preventing fiber interactions with the firstplurality of teeth 2306 and the second plurality of teeth 2308 may beattempted to prevent malfunction of the zipper 2300 caused by fiberinterference. As such, and as depicted in FIG. 23B, one or more masksmay be included with the zipper 2300 during entanglement. FIG. 23Bdepicts a cross-section of the zipper 2300 from FIG. 23A and a firstfiber layer 2314 and a second fiber layer 2316 in accordance withaspects hereof. A first mask 2318 and a second mask 2320 are positionedbetween a fiber layer (2314 and 2316, respectively) and the zipper 2300in locations where fiber entanglement is not intended to occur. A maskis an impervious (e.g., not prone to fiber entanglement) element that istemporarily (or permanently) included to prevent fibers from becomingentangled with an underlying element/scrim when entanglement occurs. Amask may be formed from any material, such as a polymer composition,metallic composition, or organic composition. In an exemplary aspect, amask may be formed from a plastic sheet material and sized to correspondwith a portion of the zipper 2300, primarily at the intersection of thefirst teeth 2306 and the second teeth 2308. The masks 2318, 2320 mayextend along a longitudinal length of the zipper 2300. In exemplaryaspects, it is contemplated that a mask may be removed or a mask may befugitive (e.g., dissolvable or disintegrable). Additionally, in anaspect, it is contemplated that a mask may be maintained relative to ascrim and/or fiber layer subsequent to entanglement. For example, themask may prevent fouling or other damage by fibers during actual use ofthe article, in an exemplary aspect.

FIG. 23C depicts that the first fiber layer 2314 and the second fiberlayer 2316 are entangled fiber binding the zipper 2300 of FIG. 23B, inaccordance with an aspect hereof. As can be seen, fibers from the firstfiber layer 2314 and fibers from the second fiber layer 2316 extendthrough the apertures 2310, 2312 of the zipper tape to fiber bind thezipper 2300 with the fiber layers 2314, 2316. As also depicted, themasks 2318, 2320 prevent entanglement of fibers with the zipper 2300teeth. Use of the masks 2318, 2320 allows for an entanglement processthat may be uniformly applied rather than avoiding entanglement up tothe teeth 2306, 2308.

FIG. 23D depicts a trimming operation of the fibers subsequent tocomplete entanglement of the assembly from FIG. 23C, in accordance withaspects hereof. As can be seen, the first plurality of fibers 2322 andthe second plurality of fibers 2324 are entangled and fiber bind thezipper 2300. It is contemplated that one or more fibers may entanglewith the tape of the zipper 2300 and/or one or more fibers may entanglewith other fibers of the fiber layers 2314, 2316 through one or moreapertures or entanglement structures of the zipper 2300 (e.g., apertures2310, 2312).

A material reduction/trimming operation, such as via a laser, water jet,knife, die, or the like then may be performed to remove fibers proximateone or more masks. In this example, a slit through the entangled fiberlayer may be made along the mask 2318 to allow removal of the mask 2318and access to the zipper 2300 for operation. Alternatively, a trimmingoperation may be performed to remove fibers overlaying the mask 2318,such as a cut along a perimeter of the mask 2318, as depicted in FIG.23D. Removal of the fibers proximate the mask may reduce, in anexemplary aspect, unintentional interference with zipper operations byfibers of the entangled fiber layer. A similar operation may beperformed on the second mask 2320.

A zipper may be incorporated into an article with a fiber-boundstructure. For example, it is contemplated a zipper may be formed in ashoe upper as a closure mechanism. A fiber-bound zipper also may beformed into an article of apparel (e.g., shirt, shorts, pants, or bra).A fiber-bound zipper also may be incorporated into outerwear (e.g.,jacket, glove, or hat). A fiber-bound zipper may be incorporated intoequipment (e.g., protective gear). Fiber binding of a zipper reduces oreliminates stitching or other bonding mechanisms that may causeincreased manufacturing costs and time. Also, fiber binding of a zipperallows for a seamless construction that provides an alternative feel toa wearer/user, a different distribution of forces to the article inwhich it is incorporated, and/or a different appearance.

Fiber binding also may serve as a tamper-proof construction. Forexample, a fiber-bound element having a mask (or no mask) may secure anitem or a volume. The volume or void may remain verifiably sealed untilthe fiber is trimmed allowing access to the scrim, which may be aclosure/opening element (e.g., zipper or hook-and-loop). Stateddifferently, delaying a trimming process provides functionalizationproof for the fiber-bound element (e.g., proof that an element has notbeen adjusted, such as zipped or unzipped).

FIGS. 24A through 24C depict fiber-bound hook-and-loop fasteners aselement scrims, in accordance with aspects hereof. While a hook-and-loopstructure is depicted, it is contemplated that any fastenerconfiguration (e.g., mushroom cap and receptacle) may be implemented.FIG. 24A depicts a hook assembly 2402 comprised of a hook fastener 2408positioned between a first fiber layer 2404 and a second fiber layer2406. A mask 2410 also is depicted masking the hooks of the hookfastener 2408. The mask 2410 limits entanglement of fibers from thefirst fiber layer 2404 with the hooks of the hook fastener 2408. A maskmay be formed from an impervious material or technique that limits fiberpenetration and/or entanglement below the mask, as previously described.

A loop assembly 2404 is also depicted in FIG. 24A. The loop assembly2404 is comprised of a first fiber layer 2412, a second fiber layer2414, and a loop fastener 2416. A mask 2418 also is depicted masking theloops of the loop fastener 2416. The hook fastener 2408 and the loopfastener 2416 are effective to cooperate to form a hook-and-loopfastening mechanism that can be engaged and disengaged to open and closea connected article, in an exemplary aspect.

FIG. 24B depicts entanglement of the first fiber layers and the secondfiber layers of the respective hook assembly and loop assembly. Asdepicted, however, the mask 2410 and the mask 2418 limit entanglement offibers with the hooks or loops of the respective assemblies. Aspreviously described with respect to the zipper 2300 in FIG. 23A, it iscontemplated that the hook fastener 2408 and/or the loop fastener 2416may be modified to provide entanglement structures. For example, one ormore apertures may be formed integrally with or through the elements inlocations that will not be obscured by a mask, such as a perimeter.Additionally, it is contemplated that entanglement structures, such asnon-linear edges, and additional structures may be incorporated with thehook fastener 2408 and/or the loop fastener 2416 to assist in achievingfiber binding of those elements to a fiber layer. It also iscontemplated that mere encasement may be sufficient to maintain the hookfastener 2408 and/or the loop fastener 2416 in a defined position of afiber material. Further, encasement may be used to temporarily maintainthe elements until a post process (e.g., energy, heat, pressure, oradhesive) may be applied. It is contemplated that the elements, such asthe hook assembly, may include a mask or an impervious backing/materialto prevent fouling of the functional portion(s) of the elements. Forexample, fibers extending through a back portion of the hook assemblyinto the hooks may reduce the gripping ability of the hooks. Therefore,a mask or impervious material may be used relative to the element toprevent fiber entanglement that could limit functional intentions of theelement.

FIG. 24C depicts a trimming operation of the assemblies from FIG. 24B,in accordance with aspects hereof. The hook fastener 2408 is fiber-boundeven after trimming allows removal of the mask 2410 and associatedfibers. This trimming operation exposes the hooks of the hook fastener2408 for use as a hook-and-loop fastener. A trimming operationassociated with the loop fastener 2416 allows for the removal of themask 2418 and associated fibers. Once removed, the loops of the loopfastener 2416 are exposed to be effectively used as a hook-and-loopfastener.

It is contemplated that any size, shape, or type of hook and/or loop maybe fiber-bound. A hook and/or loop assembly may be incorporated into anarticle with a fiber-bound structure. For example, it is contemplated ahook and/or loop assembly may be formed in a shoe upper as a closuremechanism. A fiber-bound hook and/or loop assembly also may be formedinto an article of apparel (e.g., shirt, shorts, pants, or bra). Afiber-bound hook and/or loop assembly also may be incorporated intoouterwear (e.g., jacket, glove, or hat). A fiber-bound hook and/or loopassembly also may be incorporated into equipment (e.g., protectivegear). Fiber binding a hook and/or loop assembly reduces or eliminatesstitching or other bonding mechanisms that may cause increasedmanufacturing costs and time. Also, fiber binding of a hook and/or loopassembly allows for a seamless construction that provides an alternativefeel to a wearer/user, a different distribution of forces to the articlein which it is incorporated, and/or a different appearance. Anadditional advantage of fiber binding a hook assembly is that,traditionally sewing of a hook assembly can result in thread beingtangled and breaking during use as the hooks interact and move relativeto the thread used to secure it by stitching. With fiber binding, agreater number of mechanical interactions (e.g., discrete fibersentangled) may be leveraged to secure the hook assembly (and/or loopassembly).

FIGS. 25A through 25D depict a fiber-bound element that providesdimensional offsets, in accordance with aspects hereof. FIG. 25A depictsan exemplary dimensional offset element 2500, in accordance with aspectshereof. In a specific example, it is contemplated that a dimensionaloffset element may serve as a shoe outsole, protective padding element,and the like. The dimensional offset element 2500 is comprised of aplurality of protrusion elements 2502 and a lattice structure 2504. Thelattice structure 2504 also may be referred to as a matrix that istwo-dimensional and/or three-dimensional in structure. It is understoodthat the features of the dimensional offset element 2500 are merelyexemplary in nature and are not limiting. It is contemplated thatdifferent sizes, shapes, and configurations may be implemented for thosefeatures. For example, when used as a footwear tread pattern, thedimensional offset element 2500 may have a varied pattern to accommodatedifferent portions of the footwear (e.g., toe end, heel end, ormidfoot). The plurality of protrusions 2502 may have differentcross-sectional shapes and/or sizes. The plurality of protrusions 2502may have variable offset heights (e.g., protrusion heights). The latticestructure 2504 may be nonlinear, variable in dimensions, and/ordifferent in configuration (e.g., may have a gradient in sizing,gradient in spacing, traverse cross-section shape variations,longitudinal shape variations, wavy, or crimped).

The dimensional offset element 2500 may be formed from a variety ofmaterials. In an exemplary aspect, the dimensional offset element 2500is formed from a molded polymer, such as polyurethane, ethyl-vinylacetate, silicone rubber, or the like. An exemplary material may be anelastomeric polymer. It is contemplated that the plurality ofprotrusions 2502 may be co-formed or independently formed from thelattice structure 2504. Also it is contemplated that the plurality ofprotrusions 2502 may be made from a different or similar material to thelattice structure 2504. Further, it is contemplated that the latticestructure 2504 may be omitted altogether and one or more of theplurality of protrusions 2502 may be a discrete element, in an exemplaryaspect. When a protrusion of the plurality of protrusions 2502 is adiscrete element, it is contemplated that a protrusion may have a flangeor other entanglement structure as described throughout. Therefore, thelattice structure 2504 may be integral with and/or formed from the samematerial as one or more of the plurality of protrusions 2502 or thelattice structure 2504 may be separate and distinct from one or more ofthe plurality of protrusions 2502 as an entanglement structure.

FIG. 25B is a cross-sectional view along cutline 25B of FIG. 25A, inaccordance with aspects hereof. As depicted, the plurality ofprotrusions 2502 extends from the lattice structure 2504 to extend agreater distance in the Z-direction (e.g., upwards in FIG. 25B). In anexemplary aspect, a fiber layer that fiber binds the dimensional offsetelement 2500 when entangled may have a Z-directional height from thelattice structure 2504 that is less than the plurality of protrusions2502. Stated differently, the plurality of protrusions 2502 may extendbeyond a fiber layer forming a fiber binding so that they are exposedand not covered/obscured by the fibers.

FIG. 25C depicts the dimensional offset element 2500 of FIG. 25B with afirst fiber layer 2506 and a second fiber layer 2508, in accordance withaspects hereof. As with other scrim and fiber layer combinationsdescribed herein, it is contemplated that one or more fibers in thefirst or second fiber layers 2506, 2508 may have variablecharacteristics. For example a low-melt polymer composition may form atleast a portion of the fibers, such as fibers in the first fiber layer2506. For example, it is contemplated that post entanglement, low-meltfibers may be exposed to energy causing a flowing or joining of fibersthat results in a plate or sole structure through which the dimensionaloffset element 2500 protrudes to form traction elements. The formedplate or sole structure may have different permeability (e.g., air orwater permeability), rigidity, flexibility, and/or abrasion resistancerelative to non-melted fiber layers. It is further contemplated that oneor more of the fibers may be able to join with one or more materialsforming a dimensional offset element. For example, the fibers may bondwith the dimensional offset through pressure, energy, chemicals, and/orother techniques.

FIG. 25D depicts the assembly of FIG. 25C subsequent to entanglement, inaccordance with aspects hereof. The dimensional offset element 2500 isfiber-bound through the entanglement process by encasement of thelattice structure 2504. Additionally, it is contemplated that thedimensional offset element 2500 may include a fiber-based latticestructure that is entangled with one or more fibers from the fiberlayer(s). It is further contemplated that one or more masks may be usedto prevent entanglement of one or more portions of a dimensional offsetelement. Additionally or alternatively, masking may not be used as oneor more portions may be formed from a fiber impervious material (e.g.,firm polymer or rubber) that serves as a self-masking portion. Trimmingoperations also may be implemented in various aspects to expose orotherwise clear one or more fibers from a portion. As depicted, one ormore of the plurality of protrusions 2502 extend beyond a fiber layer2510 formed from the entanglement of the first fiber layer 2506 and thesecond fiber layer 2508. As a result, the dimensional offset element2500 can provide dimensional offset from the entangled fiber layer, suchas tread for a shoe, protective padding (e.g. elastomeric or foam),enhanced durability, breathability, reduced surface contact, and/or thelike.

As explored with the element scrims above, masking is contemplated to beused in connection with any scrim. For example, it is contemplated thatmasking may be used with a scrim to prevent fiber entanglement with thescrim in one or more locations. When fibers from a fiber layer entanglewith a scrim, the characteristics of the scrim may be altered. In someinstances, the alteration of the scrim characteristics in a specificlocation may not be desired. Therefore, it is contemplated that a mask,such as a fiber impervious material (e.g., a polymer sheet) may bepositioned between the scrim and the fiber layer. Subsequent toentanglement, a trimming process may be performed to remove the fibersadjacent the mask and the mask itself. The prevention of fiberentanglement at the location of the mask therefore may allow theoriginal characteristics of the scrim to be maintained. Additionally, itis contemplated that a trimming operation and/or masking may be used toform windows where underlying engineering elements may be more visibleor ascertainable as they are not being obscured by a fiber layer.

Self-masking, as previously described, is also contemplated.Self-masking contemplates a material and/or structure that alters anentanglement characteristic, such as prohibiting entanglement,restricting entanglement, and/or altering a location of entanglement.Examples include material selection of fiber impervious materials.Generally, hard or nonporous materials resist fiber entanglement.Another example of fiber impervious structures is those with an acutedistal end. For example, conical or tapered structures can cause asplitting or separating of fibers around a portion of the structureduring entanglement. The force applied during entanglement works to movethe fibers around the structure as they entangle. Therefore,self-masking elements may be formed having a specific shape and/ormaterial to limit the use of a separate mask while achieving a maskingresult, in an exemplary aspect.

Fiber binding also may be leveraged to bind a fiber material, such as afiber-bound engineered material, to a dissimilar material at a perimeterof the fiber material. For example, a shoe upper may be formed by thefiber binding process provided herein. The shoe upper may then besecured to a sole, such as a foam sole, by entangling the fiber of theupper into and with the sole. For example, a needle may pressure-formone or more portions of the sole by pushing fibers from the fibermaterial into the sole. Fluid entanglement may alternatively be used toentangle a fiber layer with a sole structure (or any structure).Additionally, it is contemplated that the sole structure (or anystructure for an article comprised of foam or other fiber-impervious orat least fiber-resistant material) includes an entanglement structure.For example, the sole (or any component) may be formed with a co-molded,co-formed, or post-processed attachment lattice. The lattice may befiber-based or any entanglement structure/material provided herein. Theentanglement structure serves as a fiber bonding interface for thecomponent (e.g., sole) and one or more fiber layers, such as afiber-bound engineered material.

Another advantage provided by fiber binding may include edge finishing.In traditional textiles, such as weft knit or woven, individual elements(e.g., yarns or strings) may unravel or fray. The unraveling oftraditional materials may be prevented with edge finishes, such asseams, binders, and other techniques. The edge finishing techniques,however, may insert additional material, weight, cost, and processes. Afiber-bound engineered material is self-finishing. Because of theentanglement of a plurality of fibers, an edge formed during or as aresult of a cutting operation on a fiber entanglement engineeredmaterial is self-finishing without additional materials. Further yet, itis contemplated that one or more reactive fibers may be included in thefiber layer that fuse or otherwise secure to other fibers at the edge toreinforce the self-finished edge. A fiber-bound engineered material isresistant to edge failures, such as unraveling. Further yet, fiberbinding of materials susceptible to edge failures can stem thosefailures as well. For example, a scrim formed from a knit material ifcut prior to the fiber entanglement may unravel along a cut. If,however, the knit material is fiber-bound prior to being cut, thefiber-bound knit scrim is resistant to edge failure. Therefore, cutedges of fiber-bound engineered materials may be resistant to edgefailures and edge finishing techniques may be omitted.

Synthetic Leather

A fiber-bound engineered material as provided herein may be processedinto synthetic leather that maintains the engineered characteristicswhile further being classified as engineered synthetic leather. Thismaterial that is highly efficient to manufacture and also has aninfinite degree of custom engineering available, may replicate syntheticleather in an engineered material form. At least two types of syntheticleather may be formed from a fiber-bound engineered material.

A first type of synthetic leather engineered material includes aformed-fiber-bound engineered material, at least a portion of which isimpregnated with a polymer, such as silicone or polyurethane, such thatthe polymer at least partially encases the fibers. If a scrim ispresent, the polymer may also coat and least partially encase the scrimas well. Stated differently, the polymer may fill interstitial volumesof the fiber-bound engineered material. The polymer coated material thenmay be treated to form a porous structure, such as with a solvent or amechanical process. Additional processing may occur to form thefiber-bound engineered material into a synthetic (e.g., imitation)leather. For example, colorants, dyes, textures, top coats (e.g.,polyurethanes, silicones, or ethylene-vinyl acetate), and the like maybe applied at various stages to achieve a leather-like feel andappearance.

A second type of synthetic leather engineered material includes aformed-fiber-bound engineered material as provided herein wherein atleast a portion of the fibers are protein-based fibers. Examples ofprotein-based fibers are cut, chopped, or ground animal materials suchas hides, or protein-based materials which have been solubilized andre-formed into fibers. The protein-based fibers may form a compositionalso comprised of a low-melt polymer fiber, where the low-melt polymerfiber has a melt temperature or a softening temperature below asoftening temperature or decomposition temperature of the protein-basedfiber.

The composition comprised of the low-melt polymer fiber and theprotein-based fiber may also include a base fiber. The base fiber is afiber having a melt temperature, softening temperature, or decompositiontemperature above the low-melt polymer fiber. The base fiber may be anymaterial, such as a synthetic, organic, or metallic. This composition ofmaterials may form, at least in part, the fiber layer used to constructa fiber-bound engineered material.

Prior to entanglement of the fiber layer having protein-based fibers,the low-melt fibers blended with the protein-based fibers may be meltedto secure, at least temporarily, the protein-based fibers and the basefibers. The webbing formed with base fibers and protein-based fibers maythen proceed to an entanglement process. It is contemplated in the abovecomposition that the low-melt polymer may be a non-fiber form and/or aportion of a bi-component fiber with the base fiber. Also, it iscontemplated that a temporary backing material may be applied to thefiber layer prior to entanglement. The backing material may aid inmaintaining the protein-based fibers in connection with the base fibersduring the entanglement process, in an exemplary aspect. In alternativeaspects, it is contemplated that the backing material may be omitted anda scrim forming at least a portion of the fiber-bound engineeredmaterial serves to maintain the protein-based fibers in connection withthe base fibers. The resulting fiber-bound engineered material havingprotein-based fibers may provide a material with the feel and look ofleather, but with functional attributes of an engineered material.

Top coating of synthetic leather engineered materials also iscontemplated. A top coating may include one or more polymeric materials.The polymeric material may be a thermoplastic material or a thermosetmaterial. The polymeric material can include polyurethanes, polyesters,polyethers, polyamides, polyolefins including polypropylenes andpolyethylenes, polycarbonates, polyacrylates includingpolyacrylonitriles, vinyl polymers including polyvinyl butyral (PVB) andethylene vinyl acetate (EVA), aramids, any co-polymers thereof, and anycombination thereof. The coating may be applied to a surface of thesynthetic leather engineered material. The top coating may be applied ina zonal manner to provide another potential level of engineeredmaterials. For example, a first material may be applied as a top coat toincrease abrasion resistance in a desired location (e.g., toe end of ashoe). A second material may be applied in another location to achieveultraviolet light resistance. Therefore, surface coatings may be used toachieve an engineered characteristic that has an intended function at anintended location.

A synthetic leather engineered material further may be processed toachieve different results. For example, processes may be performed toform suede leather. Regardless of which technique is utilized to form asynthetic leather from the fiber-bound engineered material, theresulting product may be implemented in a variety of articles as asubstitute for traditional leather or monolithic (e.g., uniform)synthetic leather. Seams, bulk, and layers may be reduced with anengineered synthetic leather formed from a fiber-bound engineeredmaterial.

The synthetic leather may be further processed to achieve differentresults. For example processes may be performed to form suede leather.

Regardless of which technique of forming synthetic leather from thefiber-bound engineered material, the resulting product may beimplemented in a variety of articles as a substitute for traditionalleather or monolithic (e.g., uniform) synthetic leather. Seams, bulk,and layers may be reduced with an engineered synthetic leather formedfrom a fiber-bound engineered material.

Articles

While the present application provides for fiber-bound engineeredmaterials generally, many examples are directed to an article offootwear. It is understood that the concepts introduced may be appliedto a variety of articles in a variety of industries. For example, it iscontemplated that the clothing and apparel industry may leveragefiber-bound engineered materials. For example, a bra may be formed usingmaterials and techniques described herein to provide support, padding,integrated clasps, hooks, buckles, rings, adjusters, underwire, and/orsupports, and to minimize bulk. Outerwear, such as a jacket, may beformed to have functional characteristics at intended locations (e.g.,abrasion resistance from scrims at joints, water resistance from fusiblefibers at the top of shoulders, breathability in chest and back portionsfrom macro textures and/or exposed scrim elements, pockets createdthrough zonal prohibition of entanglement and closure systems fromfiber-bound element scrims like zippers and snaps). Within theupholstery industry, fiber-bound engineered materials may be leveragedto form integrated conduits of fluids or electrical elements to heatand/or cool and to provide abrasion resistance at upholstery edgesthrough scrims or fiber selection. Thermal covering, such as a heatedblanket, may be formed through one or more fiber-bound engineeredmaterials. The medical and/or safety field may leverage fiber-boundengineered materials, for example, such that element scrims can positionand maintain supportive elements, integral fastening mechanisms,sensors, and/or transmission materials relative to a patient (human oranimal), such as integral to a splint, cast, cuff, belt, wrap, mask, orother. In the automotive, aerospace, and construction industries,fiber-bound engineered materials may be leveraged to form engineeredcomponents, such as laminates, composites, or other hybrid materialsfrom fiber-bound engineered materials encased in polymers, like a resin.The sporting goods industry may leverage fiber-bound engineeredmaterials for equipment, such as gloves, hats, masks, bats, sticks,handles, padding, and the like. As such, while specific examples aremade throughout to footwear, it is understood that fiber-boundengineered materials may be implemented in a variety of industries andarticles.

Manufacturing Systems

Formation of fiber-bound engineered materials may be done in anautomated and/or manual environment. It is contemplated that afiber-bound engineered material may be formed in a continuous mannerstarting at any point, but as early as fiber creation. For example,fibers may be formed, such as through extrusion, to be laid as anonwoven batting layer. One or more scrim elements may be formedindependently or inline. For example, an engineered knit scrim may beformed at an automated loom on a production line that converges with theline forming the fiber-bound engineered material. This convergenceconcept may be used for all elements incorporated into the fiber-boundengineered material. After the scrim has been positioned, either byhuman or a pick-and-place machine, an optional fiber layer may be placedover the assembly, as provided herein. The assembly may be conveyed toan entanglement machine, such as a hyrdoentanglement machine, thatentangles the assembly into a fiber-bound engineered material. Thefiber-bound engineered material then may pass through one or moremanufacturing stations at which one or more post-processing operationsmay occur (e.g., cutting, trimming, energy application, molding,selective and/or strategic ablating, or tumbling). The fiber-boundengineered material then may enter into an article forming process, suchas an automated shoe manufacturing process, to form a dimensionalarticle (e.g., shoe) from the fiber-bound engineered material.

Throughout the process, it is contemplated that one or morecomputer-assisted machines may operate based on inputs and one or moreinstructions stored in computer readable memory, such as anon-transitory computer readable media. For example, it is contemplatedthat at least one vision system having a capture device, such as a CCDsensor, is capable of capturing data effective for identifying one ormore features to determine an article size, type, orientation, and/orquality. The input from the vision system may be used by a computingdevice for controlling one or more devices, such as a pickup tool (e.g.,vacuum, adhesion, or gripper), or a tool configured for one or more of acutting, trimming, spraying, conveyance, stitching, bonding, cleaning,heating, molding, quality control, or blowing machine, and the like. Forexample, a fiber-bound engineered material may pass along a conveyorthat is captured by a vision system. The vision system may capture animage of the fiber-bound engineered material. The image is processed bya computing device to determine a size, style, and orientation of thefiber-bound engineered material as a specific footwear upper. Thisinformation may spawn one or more instructions to be pulled from a datastore to control a pickup tool. The pickup tool picks up the fiber-boundengineered material and places the fiber-bound engineered material at adefined position and orientation for subsequent processing. Thesubsequent processing may be a post-processing operation, such as acutting, stitching, forming, bonding, cleaning, or a like process. Atleast one vision systems may be implemented throughout to ensurealignment, orientation, position, and/or quality.

It also is contemplated that during the formation of the fiber-boundengineered material, one or more automated or manual operations may beperformed. For example, a vision system and a pickup tool may be used incombination to pick up and place one or more scrim(s) on a fiber layer.The one or more scrim(s) may be selected based on feedback from thevision system or other identification systems, such as an RFID system,optical scanner, laser scanner, and the like. The pickup tool also maydetermine a position or relative location of a fiber layer onto whichthe picked-up scrim is to be placed. A computing device may determine atool path for the pickup tool to follow in order to pick up the scrimand to place the scrim on a fiber layer (or anywhere) such that anappropriate orientation and location are achieved.

Automated processing machines may be leveraged. For example, a computercontrolled cutting machine that leverages dies, lasers, water jets,blades, and the like may cut one or more portions from the fiber-boundengineered material. As previously described, the fiber-bound engineeredmaterial may have a self-finishing edge that allows for such anoperation to occur without preventative measures taken to limit frayingor raveling. In this example, a vision system may determine a locationat which the fiber-bound engineered material is positioned relative tothe cutting tool. This information then may be provided to a computingdevice such that a known tool path may be adjusted to compensate for thedetermined position/orientation of the fiber-bound engineered material.A similar process may be leveraged for other operations to be performedon the fiber-bound engineered material.

With manufacturing, it is contemplated that a customized article may beformed. For example, a consumer may select specific attributes (e.g.,size, color, fit, or function) that are specific to the consumer. Aunique fiber-bound engineered material may be manufactured in response.This could allow for customized orders, parts, and articles. This alsoallows for just-in-time manufacturing of a fiber-bound engineeredmaterial that is specific to a consumer's selections.

Post Processing

A fiber-bound engineered material may be post processed. Post processingmay further supplement engineering aspects of the materials, such aszonal application of post processing. Post processing may include, butis not limited to, tumbling, sheering, abrading (which may be selectiveand/or strategic to create areas that are thinner or more translucentthan other areas), puckering, flocking, molding, and energy application.Each of these post-processing techniques may adjust a state of one ormore materials used to form the engineered material. For example, asurface appearance/texture may be manipulated through a post-processingtechnique. Texture, feel, appearance, flexibility, and response may allbe adjusted through post processing.

By way of example, FIG. 28 depicts an article of footwear formed from amesh scrim 2810, as well as a laser or die-cut film scrim 2812. Theouter layer of fibers utilized to form the article enjoys a lowermelting point than the scrim materials and has been meltedpost-entanglement to form a transparent skin on the exterior of theupper.

Post processing may additionally include assembling a fiber-boundcomponent with one or more additional components to be included in theresultant manufactured article. For instance, FIG. 26 illustrates anexemplary article of footwear 2600 formed, at least in part, byfiber-binding particulates in a desired pattern 2610 between two fiberlayers. The fiber-bound portion of the footwear article (i.e., the upper2612) is sewn to a knit component (i.e., the collar 2614) to form theresultant article 2600.

Materials

As mentioned above for the various components, examples of suitablepolymers for the fibers, scrim, and the like can include one or morepolyesters, one or more polyamides, one or more polyurethanes, one ormore polyolefins, copolymers thereof, and blends thereof.

In one aspect, the fiber/scrim compositionally includes a one or morepolyesters. The polyester(s) can be derived from the polyesterificationof one or more dihydric alcohols (e.g., ethylene glycol, 1,3-propyleneglycol, 1,2-propylene glycol, 1,4-butanediol, 1,3-butanediol,2-methylpentanediol-1,5, diethylene glycol, 1,5-pentanediol,1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, andcombinations thereof) with one or more dicarboxylic acids (e.g., adipicacid, succinic acid, sebacic acid, suberic acid, methyladipic acid,glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid andcitraconic acid and combinations thereof).

The polyester(s) also can be derived from polycarbonate prepolymers,such as poly(hexamethylene carbonate) glycol, poly(propylene carbonate)glycol, poly(tetramethylene carbonate)glycol, and poly(nonanemethylenecarbonate) glycol. Suitable polyesters can include, by way of exampleand not limitation, polyethylene adipate (PEA), poly(1,4-butyleneadipate), poly(tetramethylene adipate), poly(hexamethylene adipate),polycaprolactone, polyhexamethylene carbonate, poly(propylenecarbonate), poly(tetramethylene carbonate), poly(nonanemethylenecarbonate), and combinations thereof.

In another aspect, the fiber/scrim compositionally includes one or morepolyamides (nylons). In some embodiments, the polyamide(s) can bederived from the condensation of polyamide prepolymers, such as lactams,amino acids, and/or diamino compounds with dicarboxylic acids, oractivated forms thereof. The resulting polyamide includes amide linkages(—(CO)NH—). Examples of suitable polyamides include, without limitation,polycarpolactum (PA6), polyhexamethyleneaidpamide (PA6,6),polyhexamethylenenonamide (PA6,9), polyhexamethylenesebacamide (PA6,10),polyamide 6/12 (PA6,12), polyenantholactum (PA7), polyundecanolactum(PA11), polylaurolactam (PA12), and combinations thereof. In furtherembodiments, the polyamide(s) may include one or more thermoplasticpolyamide copolymers, such as those under the tradename “PEBAX” fromArkema, Inc., Clear Lake, Tex.; and “SERENE” coating from Sumedics, EdenPrairie, Minn.

In another aspect, the fiber/scrim compositionally includes one or morepolyurethanes, each having one or more polyurethane copolymer chains(e.g. thermoplastic polyurethanes, thermoset polyurethanes, ionomericpolyurethane elastomers, and the like). In some embodiments, at least aportion of the polyurethane copolymer chains each include a plurality ofhard segments forming crystalline regions with other hard segments ofthe polyurethane copolymer chains, and a plurality of soft segmentscovalently bonded to the hard segments.

The polyurethane can be produced by polymerizing one or more isocyanateswith one or more polyols to produce copolymer chains having carbamatelinkages (—N(CO)O—), where the isocyanate(s) each preferably include twoor more isocyanate (—NCO) groups per molecule, such as 2, 3, or 4isocyanate groups per molecule (although, single-functional isocyanatescan also be optionally included, e.g., as chain terminating units).

Examples of suitable aliphatic diisocyanates for producing thepolyurethane copolymer chains include hexamethylene diisocyanate (HDI),isophorone diisocyanate (IPDI), butylene diisocyanate (BDI),bisisocyanatocyclohexylmethane (HMDI), 2,2,4-trimethylhexamethylenediisocyanate (TMDI), bisisocyanatomethylcyclohexane,bisisocyanatomethyltricyclodecane, norbornane diisocyanate (NDI),cyclohexane diisocyanate (CHDI), 4,4′-dicyclohexylmethane diisocyanate(H12MDI), diisocyanatododecane, lysine diisocyanate, and combinationsthereof.

Examples of suitable aromatic diisocyanates for producing thepolyurethane copolymer chains include toluene diisocyanate (TDI), TDIadducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate(MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate(TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate,para-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI),4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In someembodiments, the copolymer chains are substantially free of aromaticgroups. In some preferred embodiments, the polyurethane copolymer chainsare produced from diisocynates including HMDI, TDI, MDI, H₁₂ aliphatics,and combinations thereof.

Examples of suitable chain extender polyols for producing thepolyurethane copolymer chains include ethylene glycol, lower oligomersof ethylene glycol (e.g., diethylene glycol, triethylene glycol, andtetraethylene glycol), 1,2-propylene glycol, 1,3-propylene glycol, loweroligomers of propylene glycol (e.g., dipropylene glycol, tripropyleneglycol, and tetrapropylene glycol), 1,4-butylene glycol, 2,3-butyleneglycol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol,1,4-cyclohexanedimethanol, 2-ethyl-1,6-hexanediol,1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol, dihydroxyalkylatedaromatic compounds (e.g., bis(2-hydroxyethyl) ethers of hydroquinone andresorcinol, xylene-α,α-diols, bis(2-hydroxyethyl) ethers ofxylene-α,α-diols, and combinations thereof.

Examples of suitable soft segment polyols include polyethers,polyesters, polycarbonates, and combinations thereof. Examples ofsuitable polyethers include, but are not limited to polyethylene oxide(PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF),polytetramethylene oxide (PTMO), and combinations thereof. Examples ofsuitable polyesters include those described above. Examples of suitablepolycarbonates can be derived from the reaction of one or more dihydricalcohols (e.g., ethylene glycol, 1,3-propylene glycol, 1,2-propyleneglycol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol-1,5,diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol,cyclohexanedimethanol, and combinations thereof) with ethylenecarbonate. The soft segment polyols can be present in an amount of 5% to85% by weight, from 5% to 70% by weight, or from 10% to 50% by weight,based on the total weight of the reactant monomers.

In another aspect, the fiber/scrim compositionally includes one or morepolyolefins, which can be formed through free radical, cationic, and/oranionic polymerization. Examples of suitable polyolefins includepolyethylene, polypropylene, polybutylene, copolymers thereof, andblends thereof. The processes and articles described herein areparticularly suitable for use with polymers with limited chemical orreptation bonding capabilities (e.g., polyolefins, which aretraditionally difficult to bond well to other polymers such aspolyurethanes and polyamides).

As used herein, the term “polymer” refers to a molecule havingpolymerized units of one or more species of monomer. The term “polymer”is understood to include both homopolymers and copolymers. The term“copolymer” refers to a polymer having polymerized units of two or morespecies of monomers, and is understood to include terpolymers. As usedherein, reference to “a” polymer or other chemical compound refers oneor more molecules of the polymer or chemical compound, rather than beinglimited to a single molecule of the polymer or chemical compound.Furthermore, the one or more molecules may or may not be identical, solong as they fall under the category of the chemical compound. Thus, forexample, “a” polylaurolactam is interpreted to include one or morepolymer molecules of the polylaurolactam, where the polymer moleculesmay or may not be identical (e.g., different molecular weights and/orisomers).

An abbreviated listing of non-limiting materials contemplated to form atleast a portion of fibers, fiber layers, scrims, scrim elements, andother elements provided herein includes the following:vegetatively-derived (based on cellulose or lignin) materials (e.g.,plant-based, algae-based, or microbe-based materials), such as cotton,hemp, jute, flax, ramie, sisal, bagasse, or banana; wood-derivedmaterials, such as groundwood, lacebark, thermomechanical pulp, bleachedor unbleached kraft or sulfite pulp; animal-derived materials, such assilkworm silk, spider silk, sinew, catcut, wool, sea silk, hair(cashmere wool, mohair, angora), and fur; and mineral-derived materials,such as asbestos. Materials may also be biological derived fibrousproteins or protein filaments.

Another abbreviated listing of non-limiting materials contemplated toform at least a portion of fibers, fiber layers, scrims, scrim elements,and other elements provided herein includes the following: regeneratednatural materials such as regenerated cellulose (Tencel, Rayon, Modal,bamboo fiber, seacell fiber, cellulose diacetate, and cellulosetriacetate); collagen or peptide-based materials; fibers derived fromprocessed animal products such as processed animal hides (e.g.,leather); metallic materials; carbon fiber; silicon carbide fiber;fiberglass; and mineral fibers.

Yet another abbreviated listing of non-limiting materials contemplatedto form at least a portion of fibers, fiber layers, scrims, scrimelements, and other elements provided herein includes the following:synthetic polymers, polyesters (e.g., PET, PBT, and PTT), polyamides(nylon), polyolefins (e.g., polyethylene, polypropylene and polybutyleneand UHMPE), polyurethanes, thermoplastic polyurethanes, polycarbonates,aromatic polyamids (aramids), phenol-formaldehyde (PF), polyvinylchloride (PVC) fiber, acrylic polyesters, liquid crystalline polymers,copolymers of two or more of the above polymers, mixtures of two or moreof the above polymers, and fiber-reinforced polymers (e.g., fiberglass).

Individual elements can be made from polymeric materials comprising orconsisting essentially of one or more of the above polymers.

Individual elements can be made from two or more different polymericmaterials (i.e., not just as mixtures, but as separate components of amulti-component fiber, such as configured in the form of segmented pie,islands in the sea, sheath/core format, etc.).

Carrier Screens

As previously described, fiber binding is a process in which fibers fromone or more fiber layers are entangled to form a complex compositematerial that is engineered for an article. The one or more fiber layersserve as a platform and a binder onto which additional materials aresecured to build a unique hybrid composite material that is consolidatedinto a single material through entanglement. The entanglement causes thefibers of the one or more fiber layers to physically interact with andlock in the materials to create a cohesive and complete material thatcan be formed into an article. The materials added to the fiber layer(s)and the materials forming the fiber layer(s) can be deliberately and/orstrategically placed to achieve an intended functional characteristic atan intended relative location that allows for a highly engineeredmaterial to be formed as a complex composite that is consolidated into asingle material through entanglement.

Formation of fiber-bound engineered materials may be performed in anautomated and/or manual environment. In aspects, formation offiber-bound engineered materials may be performed utilizing carrierscreens. Carrier screens have a mesh-like construction which includes aplurality of apertures. In some examples, the apertures are formedbetween the intersections of a plurality of linear elements such asfilaments, yarns, cords, or wires. The linear elements can take the formof vertical elements and a plurality of horizontal elements. In otherexamples, the apertures are formed in a film or sheet. As such, carrierscreens provide a permeable platform onto which one or more fiber layersand/or scrims may be placed during fiber-bound engineered materialformation. Carrier screens further may provide a mechanism for holdingfibers forming one or more fiber layers and/or scrims in place duringprocessing. By way of example, in conveyor manufacturing of fiber-boundengineered materials, carrier screens may be provided on a first surfaceof the input materials (fiber layer(s) and/or scrim(s)) to act as aconveyor belt onto which such materials may be placed. Optionally, on anopposite surface of the input materials, a second carrier screen may beplaced to maintain the materials in the desired position for processing.Stated differently, the input materials may be positioned on one carrierscreen, or sandwiched between two or more carrier screens such that thematerials are positionally maintained prior to and during entanglement.In this way, carrier screens provide a permeable platform, andadditionally may provide a permeable material-holding mechanism, suchthat fluid (e.g., water) may pass through the carrier screen(s) andentangle the fiber layer(s) and/or scrim(s) with one another to form afiber-bound engineered material.

Formation of fiber-bound engineered materials utilizing carrier screenscan be advantageous in a variety of manufacturing scenarios. Forinstance, use of carrier screens is advantageous for aligning andregistering fiber layer(s) and/or scrim(s), including dimensionallysmall or delicate material inputs and masks that are difficult to feedinto an entangling device in other ways without losing proper alignmentand registration, or desired shape dimensions. Additionally, carrierscreens are advantageous for holding shaped fiber pieces in place forprocessing that, post-entanglement, will form stabilizing bordersections adjacent to exposed scrim sections (that is, sections of ascrim that are exposed without additional fiber binding in order tocreate zones of, for example, enhanced breathability, elasticity, and/ordrape in, e.g., articles of apparel or footwear). Further, carrierscreens are advantageous to keep small material inputs such as loosefibers or masks in place and protected during processing. Use of carrierscreens in the formation of fiber-bound engineered materials also mayimpart a surface texture onto the output fiber-bound material. Forinstance, if a screen includes a first portion having a first textureand a second portion having a second texture on the same side thereof,if a screen includes a different screen texture on opposing sidesthereof, or if a screen includes any combination of varying textures onone or both sides thereof, multiple different textures may be impartedonto the output fiber-bound material. Similarly, if two carrier screensare utilized on opposing surfaces of the material inputs, an outputfiber-bound engineered material may be produced having a differenttexture on each surface thereof. Still further, carrier-screen-mediatedentanglement allows manufacture of fiber-bound components tonear-net-shape which permits the substantial reduction of scrap wasteresulting from post-processing trimming operations. In screen-lessentangling, for instance, where continuous fiber and scrim rollsthemselves are utilized to advance the material inputs through theentangler, the resultant fiber-bound components often need to be cutfrom a full roll width, with unneeded sections being discarded, creatingadditional waste and expense.

Suitable carrier screens may be comprised of any material that is robustenough to withstand use under pressures exerted by hydroentangling fluidstreams. (It should be noted that although the term “hydroentangling” or“hydroentanglement” are utilized throughout the present description,fluid entanglement utilizing any suitable fluid is contemplated. Use ofthese terms is not intended to limit the scope of aspects of the presentapplication to fluid entanglement utilizing water.) By way of example, amesh textile, for instance one formed from synthetic polymeric fiberssuch as yarns including monofilament yarns or coated fiberglassfilaments, such as is used for window screens, may be utilized as acarrier screen, as may polymer extrusions, films, or cut netting.Carrier screens further may be comprised of a woven metal linear elementmesh, e.g., aluminum wire mesh, bronze wire mesh, or a multiple-materialwire composition mesh (e.g., a copper/zinc composition wire mesh), suchas is often used for window screens. Perforated films or sheets, such asperforated extruded polymeric films and expanded perforated metal sheetscan also be used as carrier screens. Suitable carrier screens may bedimensionally stable during use, while at the same time being flexibleenough to move through the required geometries of the fiber-bindingprocessing stages. Additionally, suitable carrier screens may conformenough to match the surface profile of the materials being entangledboth before and after entanglement. Suitable carrier screens may beeasily separated from, and removable from, the entangled materials thatare transported and/or supported. That is, suitable carrier screens maynot permanently entangle with the materials that are being carriedand/or supported, or may permanently entangle with only a portion orzone of the materials that are being carried and/or supported. In someexamples, suitable carrier screens may have little to no elongation inthe length or width directions and/or may undergo no permanentdeformation as a result of passing through the stations of thehydroentangler. Accordingly, aspects of the present applicationcontemplate woven, knit, braided, or stamped perforated constructionsfor carrier screens. Suitable carrier screens may be reusable (as isuseful to reduce waste) or single use.

As previously set forth, carrier screens described herein have amesh-like construction which includes a plurality of apertures formedbetween the intersections of a plurality of vertical linear elements anda plurality of horizontal linear elements forming a mesh-likeconstruction. The size of the apertures in a carrier screen typically isstated as a quantity of apertures across a one-inch square portion ofthe carrier screen (warp apertures) and a quantity of apertures down thesame one-inch square portion of the carrier screen (fill apertures). Forinstance, in aspects hereof, suitable carrier screens may include, byway of example only, 15×10 (indicating 15 warp apertures and 10 fillapertures in a one-inch square portion of the screen), 18×16 (indicating18 warp apertures and 16 fill apertures in a one-inch square portion ofthe screen), 20×20 (indicating 20 warp apertures and 10 fill aperturesin a one-inch square portion of the screen), 17×20 (indicating 17 warpapertures and 20 fill apertures in a one-inch square portion of thescreen); 18×14 (indicating 18 warp apertures and 14 fill apertures, or20×30 (indicating 20 warp apertures and 30 fill apertures in a one-inchsquare portion of the screen). Stated more generally, in aspects,suitable carrier screens may include a quantity of warp aperturesbetween 14 and 20. In further aspects, suitable carrier screens mayinclude a quantity of warp apertures between 16 and 20. In aspects,suitable carrier screens may include a quantity of fill aperturesbetween 14 and 30. In further aspects, suitable carrier screens mayinclude a quantity of fill apertures between 16 and 20. While exemplaryranges are provided herein, it is understood that any suitable number ofwarp and fill apertures may be utilized within aspects of the presentapplication.

In addition to the number of apertures per square inch, the size of theapertures in a carrier screen may be altered by the diameter of thelinear element utilized to form the carrier screen. The larger thediameter of the linear element, the smaller the apertures in theresultant carrier screen (assuming the same number of warp and fillapertures). Exemplary linear element diameters include, by way ofexample only, 0.005 mm to 0.03 mm Further exemplary linear elementdiameters include, by way of example only, 0.01 mm to 0.025 mm Stillfurther exemplary linear element diameters include, by way of exampleonly, 0.01 mm to 0.02 mm While exemplary diameter ranges are providedherein, it is understood that any suitable linear element diameter maybe utilized within aspects of the present application.

As the carrier screens described herein have a mesh-like constructionwhich includes a plurality of apertures penetrating the entire depth ofthe carrier screen, contemplated carrier screens are permeable tofluids, including liquids. For use in hydroentangling, suitable carrierscreens include apertures which provide the liquid with a substantiallystraight path from a first side of the carrier screen to a second sideof the carrier screen, allowing the liquid to move into, through, andout the other side thereof while retaining a pressure sufficient toentangle the fibers located on the screen(s). In other words, suitablecarrier screens include apertures of sufficient number and size to allowfluids to act with the force required to entangle the input materialsand form a fiber-bound engineered material. If splitting of microfibersalso is required, suitable carrier screens have apertures of sufficientnumber and size to allow the pressure of the fluid jets to separate thefiber segments.

Aspects hereof contemplate that sections of a carrier screen may besolid (i.e., without apertures), for instance in a predetermined patternor design, such that the solid sections provide a masking effect inrelation to the materials being processed. Use of a carrier screenhaving strategically situated sections that are variably solid andpermeable may create sections of entangled and non-entangled materialsin the resulting fiber-bound engineered materials. Additionally oralternatively, a first section of a carrier screen may include apertureswhich differ in size or number as compared to a second section of thecarrier screen. These first and second sections can be present in apredetermined pattern or design. Use of a carrier screen havingstrategically situated first and second sections may create sections offirst and second entangled materials in the resulting fiber-boundengineered materials, wherein the first and second sections havediffering levels of entanglement or density. In certain aspects hereof,first and second sections may have differing levels of entanglement ordensity that differs by at least 10%, each of the first and secondsections having a surface area of at least 0.25 cm².

With reference to FIG. 32, an exemplary conveyor-type configuration 3200for forming fiber-bound engineered materials utilizing carrier screensis illustrated. The configuration 3200 includes a fluid-permeable firstcarrier screen 3210. The illustrated first carrier screen 3210 acts as acarrier for the input materials prior to and during processing. Theconfiguration 3200 includes a first fiber layer 3212 comprising a firstplurality of fibers. The first plurality of fibers may be homogenous orheterogeneous, and may be formed as a nonwoven material that issometimes referred to as batting. Batting may be formed from a singlestratum of fibers or a plurality of strata of fibers. Each stratum mayhave a different or a similar composition of fibers. Batting may beformed as a continuous material (e.g., a rolled good) or it may beformed as a discrete element (e.g., batch goods). As illustrated, thefirst fiber layer 3212 is comprised of a plurality of pre-sized, cutfiber batting pieces that may be manually or automatically placed on thefirst carrier screen 3210. Once the first fiber layer 3212 is in place,scrims and other desired elements (e.g., textiles, cables, elementsformed of thermoplastic materials, foams, shaped polymeric or metalcomponents, and the like) 3214 are placed (automatically or manually) on(or adjacent and overlapping in a Z-directional placement) the firstfiber layer 3212. In the illustrated configuration 3200, the scrims andother desired elements 3214 are illustrated on a roll (which may includea fugitive backing 3216 that is dissolved or otherwise removed duringprocessing). For example, the fugitive backing 3216 may be formed of awater-soluble polymeric material, such as a polymeric materialcomprising water-soluble polyvinyl alcohol. Though not illustrated inFIG. 32, aspects hereof contemplate individually placed scrims and/orother desired elements as well.

On top of the scrims and other desired elements 3214 (or adjacent andoverlapping in a Z-directional placement), an optional second fiberlayer may be placed. The illustrated configuration 3200 does not includea second fiber layer but such configuration is described more fullybelow with reference to FIG. 33. When present, the second fiber layermay be manually or automatically placed on the scrims and other desiredelements 3214. In aspects, a fluid-permeable second carrier screen 3218then may be placed on the scrim or other desired elements 3214 (or onthe second fiber layer, when present). The second carrier screen 3218,in cooperation with the first carrier screen 3210, holds the inputmaterials (fiber layer(s), scrims and other desired elements) in placeand under tension. The material input/carrier screen assembly may beconveyed to an entanglement machine, such as a hydroentanglementmachine, that entangles the assembly into a fiber-bound engineeredmaterial.

In aspects, subsequent to entanglement, the first and second carrierscreens 3210, 3220 may be removed and a fiber-bound, engineered materialmay be output. In such aspects, the fiber-bound engineered material thenmay pass through one or more manufacturing stations at which one or morepost-processing operations may occur (e.g., cutting, trimming, energyapplication, application of colorants, dyes and finishes, application ofimpregnation polymers, molding, or tumbling). In alternative aspects,the first and second carrier screens 3210, 3220 may be maintained inplace after entanglement and the fiber-bound, engineered material may betransported through one or more post-processing stations (for instance,for application of thermal energy (e.g., for drying), addition ofcolorants, dyes and/or finishes, or for the application of impregnationfibers). Subsequent to such post-processing operations, the fiber-boundengineered material may enter into an article forming process, such asan automated shoe manufacturing process, to form a dimensional article(e.g., shoe) from the fiber-bound engineered material.

Turning now to FIG. 33, a second exemplary conveyor-type configuration3300 for forming fiber-bound engineered materials utilizing carrierscreens is illustrated. The configuration 3300 includes afluid-permeable first carrier screen 3310. The illustrated first carrierscreen 3310 acts as a carrier for the input materials prior to andduring processing. The configuration 3300 includes a first fiber layer3312 comprised of a plurality of pre-sized, cut fiber batting piecesattached to a minimal or fugitive roll that is dissolved or otherwiseremoved during processing. Once the first fiber layer 3312 is in place,scrims and other desired elements (e.g., textiles, cables, elementsformed of thermoplastic materials, foams, shaped polymeric or metalcomponents, and the like) 3314 are placed (automatically or manually) on(or adjacent and overlapping in a Z-directional placement) the firstfiber layer 3312. In the illustrated configuration 3300, the scrims andother desired elements 3314 are illustrated on a roll (which also mayinclude a fugitive backing 3316 that is dissolved or otherwise removedduring processing). Though not illustrated in FIG. 33, aspects hereofcontemplate individually placed scrims and/or other desired elements aswell.

On top of the scrims and other desired elements 3314 (or adjacent andoverlapping in a Z-directional placement), an optional second fiberlayer may be placed. The illustrated configuration 3300 includes asecond fiber layer 3318 comprised of a plurality of pre-sized fiberpieces attached to a minimal or fugitive roll that is dissolved orotherwise removed during processing. The second fiber layer 3318 may bemanually or automatically placed on the scrims and other desiredelements 3314. In aspects, a fluid-permeable second carrier screen 3320then may be placed on the second fiber layer 3318. The second carrierscreen 3320, in cooperation with the first carrier screen 3310, holdsthe input materials (fiber layer(s), scrims and other desired elements)in place and under tension. The material input/carrier screen assemblymay be conveyed to an entanglement machine, such as a hydroentanglementmachine, that entangles the assembly into a fiber-bound engineeredmaterial.

Subsequent to entanglement, the first and second carrier screens 3310,3320 may be removed and a fiber-bound, engineered material may beoutput. The fiber-bound engineered material then may pass through one ormore manufacturing stations at which one or more post-processingoperations may occur (e.g., cutting, trimming, energy application,application of colorants, dyes and finishes, application of impregnationpolymers, molding, or tumbling). In alternative aspects, the first andsecond carrier screens 3310, 3320 may be maintained in place afterentanglement and the fiber-bound, engineered material may be transportedthrough one or more post-processing stations (for instance, forapplication of thermal energy (e.g., for drying), addition of colorants,dyes and/or finishes, or for the application of impregnation fibers).The fiber-bound engineered material then may enter into an articleforming process, such as an automated shoe manufacturing process, toform a dimensional article (e.g., shoe) from the fiber-bound engineeredmaterial.

With reference now to FIG. 34, a third exemplary conveyor-typeconfiguration 3400 for forming fiber-bound engineered materialsutilizing carrier screens is illustrated. The configuration 3400includes a fluid-permeable first carrier screen 3410. The illustratedfirst carrier screen 3410 acts as a carrier for the input materialsprior to and during processing. The configuration 3400 includes a firstfiber layer 3412 comprised of a plurality of loose fibers that aredistributed onto the first carrier screen 3410. Once the first fiberlayer 3412 is in place, scrims and other desired elements (e.g.,textiles, cables, elements formed of thermoplastic materials, foams,shaped polymeric or metal components, and the like) 3414 are placed(automatically or manually) on (or adjacent and overlapping in aZ-directional placement) the first fiber layer 3412. In the illustratedconfiguration 3400, the scrims and other desired elements 3414 areillustrated on a roll (which may include a fugitive backing 3416 that isdissolved or otherwise removed during processing). Though notillustrated in FIG. 34, aspects hereof contemplate individually placedscrims and/or other desired elements as well.

On top of the scrims and other desired elements 3414 (or adjacent andoverlapping in a Z-directional placement), an optional second fiberlayer may be placed. The illustrated configuration 3400 includes asecond fiber layer 3418 comprised of a plurality of loose fibers. Thesecond fiber layer 3418 may be manually or automatically distributedonto the scrims and other desired elements 3414. A fluid-permeablesecond carrier screen 3420 then may be placed on the second fiber layer3418. The second carrier screen 3420, in cooperation with the firstcarrier screen 3410, holds the input materials (fiber layer(s), scrimsand other desired elements) in place and under tension. The materialinput/carrier screen assembly may be conveyed to an entanglementmachine, such as a hydroentanglement machine, that entangles theassembly into a fiber-bound engineered material.

Subsequent to entanglement, the first and second carrier screens 3410,3420 may be removed and a fiber-bound, engineered material may beoutput. The fiber-bound engineered material then may pass through one ormore manufacturing stations at which one or more post-processingoperations may occur (e.g., cutting, trimming, energy application,application of colorants, dyes and finishes, application of impregnationpolymers, molding, or tumbling). In alternative aspects, the first andsecond carrier screens 3410, 3420 may be maintained in place afterentanglement and the fiber-bound, engineered material may be transportedthrough one or more post-processing stations (for instance, forapplication of thermal energy (e.g., for drying), addition of colorants,dyes and/or finishes, or for the application of impregnation fibers).The fiber-bound engineered material then may enter into an articleforming process, such as an automated shoe manufacturing process, toform a dimensional article (e.g., shoe) from the fiber-bound engineeredmaterial.

In an exemplary aspect hereof, method of forming a component (forinstance, a component of an article of footwear, an apparel component,or a sporting equipment component) is provided. The method comprisesplacing a fiber layer adjacent a first carrier screen, the fiber layercomprising a first plurality of fibers. The method further comprisesplacing a scrim on the first fiber layer, wherein the scrim comprises asecond plurality of fibers, wherein the scrim includes a first surfaceand an opposite second surface, and wherein the scrim first surface isadjacent and overlapping the first fiber layer in a Z-directionalplacement. Still further, the method comprises entangling at least aportion of the first plurality of fibers with at least a portion of thesecond plurality of fibers.

In another exemplary aspect hereof, a method of forming a component (forinstance, a component of an article of footwear, an apparel component,or a sporting equipment component) is provided. The method comprisesplacing a first fiber layer adjacent a first carrier screen, the firstfiber layer comprising a first plurality of fibers. The method furthercomprises placing a scrim adjacent the first fiber layer, the scrimhaving a first surface and an opposite second surface, the scrim firstsurface being adjacent and overlapping the first fiber layer in a firstZ-directional placement. Still further, the method comprises placing asecond fiber layer on the second surface of the scrim, the second fiberlayer comprising a second plurality of fibers and having a first surfaceand an opposite second surface, the first surface of the second fiberlayer being adjacent and overlapping the second surface of the scrim ina second Z-directional placement. Further still, the method comprisesentangling at least a portion of the first plurality of fibers with atleast a portion of the second plurality of fibers.

Exemplary aspects hereof further provide a method of forming a component(for instance, a component of an article of footwear, an apparelcomponent, or a sporting equipment component). The method comprisesplacing a first fiber layer adjacent a first carrier screen, the firstfiber layer comprising a first plurality of fibers, wherein the firstplurality of fibers comprises at least one of a plurality of loosefibers, a plurality of shaped fiber pieces, and a plurality of fibersadhered to a fugitive backing; placing a scrim adjacent the first fiberlayer, the scrim having first surface and an opposite second surface,the scrim first surface being adjacent and overlapping the first fiberlayer in a first Z-directional placement; placing a second fiber layeron the second surface of the scrim, the second fiber layer comprising asecond plurality of fibers and having a first surface and an oppositesecond surface, the first surface of the second fiber layer beingadjacent and overlapping the second surface of the scrim in a secondZ-directional placement; placing a second carrier screen adjacent thesecond surface of the second fiber layer; and entangling at least aportion of the first plurality of fibers with at least a portion of thesecond plurality of fibers.

From the foregoing, it will be seen that aspects of this invention arewell adapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and sub-combinations are ofutility and may be employed without reference to other features andsub-combinations. This is contemplated by and is within the scope of theclaims.

While specific elements and steps are described in connection to oneanother, it is understood that any element and/or steps provided hereinare contemplated as being combinable with any other elements and/orsteps regardless of explicit provision of the same while still beingwithin the scope provided herein. Since many possible embodiments may bemade of the disclosure without departing from the scope thereof, it isto be understood that all matter herein set forth or shown in theaccompanying drawings is to be interpreted as illustrative and not in alimiting sense.

Claims are provided hereinafter. Although the fiber-bound engineeredmaterials formed utilizing engineered scrims and methods ofmanufacturing such materials are described above by referring toparticular aspects, it should be understood that modifications andvariations could be made without departing from the intended scope ofprotection provided by the following claims. It is contemplated that anyone of the dependent claims may multiply depend from other claims of thesame independent claim set. Therefore, while not specifically listed as“[t]he component of claims X-Y, wherein . . . ” or “[t]he component ofclaims X-Y further comprising . . . ,” the Applicant contemplates eachdependent claim may be multiply dependent in some aspects.

As used herein and in connection with the features listed hereinafter,the terminology “any of features” or similar variations of saidterminology is intended to be interpreted such that features may becombined in any combination. For example, an exemplary feature 4 mayindicate the method/apparatus of any of features 1 through 3, which isintended to be interpreted such that elements of feature 1 and feature 4may be combined, elements of feature 2 and feature 4 may be combined,elements of feature 3 and 4 may be combined, elements of features 1, 2,and 4 may be combined, elements of features 2, 3, and 4 may be combined,elements of features 1, 2, 3, and 4 may be combined, and/or othervariations. Further, the terminology “any of features” or similarvariations of said terminology is intended to include “any one offeatures” or other variations of such terminology, as indicated by someof the examples provided above.

Exemplary Features Having Multiple Dependency:

Feature 1. A method of forming a component, the method comprising:placing a first fiber layer adjacent a first carrier screen, the firstfiber layer comprising a first plurality of fibers; placing a scrimadjacent the first fiber layer, wherein the scrim comprises a secondplurality of fibers, wherein the scrim includes a first surface and anopposite second surface, and wherein the scrim first surface is adjacentand overlapping the first fiber layer in a Z-directional placement; andentangling at least a portion of the first plurality of fibers with atleast a portion of the second plurality of fibers.

Feature 2. The method of feature 1, wherein the component is one of acomponent of an article of footwear, an apparel component, or a sportingequipment component.

Feature 3. The method of any of features 1 and 2, wherein the componentis a component of an article of footwear.

Feature 4. The method of any of features 1 through 3, wherein thecomponent is an upper of the article of footwear.

Feature 5. The method of feature 4, wherein the upper of the article offootwear is comprised of a medial portion, a lateral portion, and aforefoot region of the article of footwear.

Feature 6. The method of any of features 1 through 5, wherein theentangling is performed, at least in part, with a fluid stream.

Feature 7. The method of any of features 1 through 6, wherein the firstplurality of fibers comprises, at least in part, a plurality of loosefibers.

Feature 8. The method of any of features 1 through 6, wherein the firstplurality of fibers comprises, at least in part, a plurality of shapedfiber pieces.

Feature 9. The method of any of features 1 through 6, wherein the firstplurality of fibers, at least in part, is adhered to a fugitive backing.

Feature 10. The method of any of features 1 through 9, furthercomprising placing a second carrier screen adjacent the second surfaceof the scrim.

Feature 11. The method of feature 10, wherein at least one of the firstcarrier screen and the second carrier screen is formed of a meshcomprised, at least in part, of a monofilament polymeric yarn,fiberglass filament, plastic fiber polyester fiber, a polymer extrusion,a film, cut netting, woven aluminum, woven bronze, or amultiple-material woven composition.

Feature 12. The method of any of features 10 and 11, wherein at leastone of the first carrier screen and the second carrier screen is formedof a mesh including one or more warp apertures and one or more fillapertures.

Feature 13. The method of any of features 10 through 12, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including a plurality of warp apertures and a pluralityof fill apertures, wherein a quantity of warp apertures is between 14and 20, and wherein a quantity of fill apertures is between 14 and 30.

Feature 14. The method of any of features 10 through 12, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including a plurality of warp apertures and a pluralityof fill apertures, wherein a quantity of warp apertures is between 16and 20, and wherein a quantity of fill apertures is between 16 and 20.

Feature 15. The method of any of features 11 through 14, wherein themesh comprises a diameter of 0.005 mm to 0.03 mm

Feature 16. The method of any of features 11 and 14, wherein the meshcomprises a diameter of 0.01 mm to 0.025 mm

Feature 17. The method of any of features 11 through 14, wherein themesh comprises a diameter of 0.01 mm to 0.02 mm

Feature 18. The method of any of features 1 through 17, wherein thefirst plurality of fibers comprises, at least in part, one selected fromone selected from polyurethanes, thermoplastic polyurethanes,polyesters, polyethers, polyamides, polyolefins, polycarbonates,polyacrylates, aramids, cellulosic materials, glass, carbon, metals,minerals, co-polymers thereof, and any combinations thereof.

Feature 19. The method of any of features 1 through 18, furthercomprising applying energy to the component subsequent to entangling.

Feature 20. The method of any of features 1 through 19, furthercomprising impregnating the component with a polymer and forming thecomponent into a synthetic leather.

Feature 21. The method of any of features 1 through 20, wherein thefirst plurality of fibers comprises a protein-based material.

Feature 22. The method of any of features 1 through 20, wherein thefirst plurality of fibers comprises an animal-derived material and apolymer material.

Feature 23. The method of any of features 1 through 22, wherein thescrim is formed as a knit, woven, braided, non-woven,direct-fiber-placed, molded, cast, extruded, deposited, expanded,reductions-formed, 3D-printed, sheet, film, or embroidered element.

Feature 24. The method of any of features 1 through 23, wherein thecomponent has a first functional zone and a second functional zone, thefirst functional zone having a functional characteristic that differsfrom the same functional characteristic of the second functional zone.

Feature 25. The method of feature 24, wherein the functionalcharacteristic differs by at least 10% between the first and secondfunctional zones.

Feature 26. The method of any of features 24 and 25, wherein thefunctional characteristic is one of air permeability, porosity, moisturewicking capacity, water resistance, water proofing, imperviousness,hydrophobicity, fineness, burst strength, toughness, sheer forceresistance, recovery after elongation, bending modulus, coldflexibility, resistance to crack propagation, thermal degradationresistance, thermal glass transition temperature, melting point,capacity to take a heat set, Z-directional thickness, gauge, specificgravity, density per unit area, weight per unit area, surface area,continuity of surface, dimensional stability, resistance to compressionset, deformability, creep resistance, bonding capacity, adhesivecompatibility, electrical conductance, light transmittance, fluidtransfer capability, washability, resistance to shrinkage, resistance tosolvents, colorability, colorfastness, resistance to UV lightdegradation, microbial resistance, moisture permeability, modulus ofelasticity, abrasion resistance, resilience, durability, strength,tensile strength, hardness, flex elongation, tear strength, and thermalinsulative capacity.

Feature 27. A component formed utilizing the method of any of features 1through 26.

Feature 28. A component comprising: a first fiber layer comprising afirst plurality of fibers; and a scrim comprising a second plurality offibers, wherein the scrim includes a first surface and an oppositesecond surface, wherein at least a portion of the first plurality offibers is entangled with at least a portion of the second plurality offibers utilizing at least one carrier screen, and wherein the scrimfirst surface is adjacent and overlapping the first fiber layer in aZ-directional placement.

Feature 29. The component of feature 28, wherein the component is one ofa component of an article of footwear, an apparel component, or asporting equipment component.

Feature 30. The component of any of features 28 and 29, wherein thecomponent is a component of an article of footwear.

Feature 31. The component of any of features 28 through 30, wherein thecomponent is an upper of the article of footwear.

Feature 32. The component of any of features 28 through 31, wherein theupper of the article of footwear is comprised of a medial portion, alateral portion, and a forefoot region of the article of footwear.

Feature 33. The component of any of features 28 through 32, wherein thefirst plurality of fibers comprises, at least in part, a plurality ofloose fibers.

Feature 34. The component of any of features 28 through 32, wherein thefirst plurality of fibers comprises, at least in part, a plurality ofshaped fiber pieces.

Feature 35. The component of any of features 28 through 32, wherein thefirst plurality of fibers, at least in part, is adhered to a fugitivebacking.

Feature 36. The component of any of features 28 through 35, wherein theat least one carrier screen is formed of a mesh comprised, at least inpart, of a monofilament polymeric yarn, fiberglass filament, plasticfiber, polyester fiber, a polymer extrusion, a film, cut netting, wovenaluminum, woven bronze, or a multiple-material woven composition.

Feature 37. The component of any of features 28 through 36, wherein theat least one carrier screen is formed of a mesh including one or morewarp apertures and one or more fill apertures.

Feature 38. The component of any of features 28 through 37, wherein theat least one carrier screen is formed of a mesh including a plurality ofwarp apertures and a plurality of fill apertures, wherein a quantity ofwarp apertures is between 14 and 20, and wherein a quantity of fillapertures is between 14 and 30.

Feature 39. The component of any of features 28 through 37, wherein theat least one carrier screen is formed of a mesh including a plurality ofwarp apertures and a plurality of fill apertures, wherein a quantity ofwarp apertures is between 16 and 20, and wherein a quantity of fillapertures is between 16 and 20.

Feature 40. The component of any of features 37 through 39, wherein themesh comprises a diameter of 0.005 mm to 0.03 mm

Feature 41. The component of any of features 37 and 39, wherein the meshcomprises a diameter of 0.01 mm to 0.025 mm

Feature 42. The component of any of features 37 through 39, wherein themesh comprises a diameter of 0.01 mm to 0.02 mm

Feature 43. The component of any of features 28 through 42, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises, at least in part, one selected at least one selectedfrom polyurethanes, thermoplastic polyurethanes, polyesters, polyethers,polyamides, polyolefins, polycarbonates, polyacrylates, aramids,cellulosic materials, glass, carbon, metals, minerals, co-polymersthereof, and any combinations thereof.

Feature 44. The component of any of features 28 through 43, wherein thecomponent is impregnated forming a synthetic leather.

Feature 45. The component of any of features 28 and 44, wherein thefirst plurality of fibers comprises a polymeric composition comprised ofat least one polymer.

Feature 46. The component of any of features 28 through 45, wherein thefirst plurality of fibers comprises at least one selected frompolyurethanes, thermoplastic polyurethanes, polyesters, polyethers,polyamides, polyolefins, polycarbonates, polyacrylates, aramids,cellulosic materials, glass, carbon, metals, minerals, co-polymersthereof, and any combinations thereof.

Feature 47. The component of any of features 28 through 45, wherein thefirst plurality of fibers is comprised of at least one polymer thatconsists essentially of at least one selected from polyurethanes,thermoplastic polyurethanes, polyesters, polyethers, polyamides,polyolefins, polycarbonates, polyacrylates, aramids, cellulosicmaterials, glass, carbon, metals, minerals, co-polymers thereof, and anycombinations thereof.

Feature 48. The component of any of features 28 through 47, wherein thefirst plurality of fibers is comprised of a staple fiber or a continuousfilament fiber.

Feature 49. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a linear massdensity measurement of 1 denier per filament (dpf) to 9 dpf.

Feature 50. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a linear massdensity measurement of 1 denier per filament (dpf) to 4 dpf.

Feature 51. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a linear massdensity measurement of 0.001 denier per filament (dpf) to 0.999 dpf.

Feature 52. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a widthmeasurement of 200 microns to 100 nanometers.

Feature 53. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a widthmeasurement of 100 microns to 100 nanometers.

Feature 54. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a widthmeasurement of 25 microns to 0.01 microns.

Feature 55. The component of any of features 28 through 48, wherein thefirst plurality of fibers is comprised of a fiber having a widthmeasurement of 10 microns to 0.01 microns.

Feature 56. The component of any of features 28 through 55, wherein thefirst fiber layer is a non-woven textile.

Feature 57. The component of any of features 28 through 56, wherein thefirst plurality of fibers comprises a protein-based material.

Feature 58. The component of any of features 28 through 57, wherein thefirst plurality of fibers comprises an animal-derived material and apolymer material.

Feature 59. The component of any of features 28 through 58, wherein thescrim is formed as a knit, woven, braided, non-woven,direct-fiber-placed, molded, cast, extruded, deposited, expanded,reductions-formed, 3D-printed, sheet, film, or embroidered element.

Feature 60. The component of any of features 28 through 59, wherein thecomponent has a first functional zone and a second functional zone, thefirst functional zone having a functional characteristic that differsfrom the same functional characteristic of the second functional zone.

Feature 61. The component of feature 60, wherein the functionalcharacteristic differs by at least 10% between the first and secondfunctional zones.

Feature 62. The component of any of features 60 and 61, wherein thefunctional characteristic is one of air permeability, porosity, moisturewicking capacity, water resistance, water proofing, imperviousness,hydrophobicity, fineness, burst strength, toughness, sheer forceresistance, recovery after elongation, bending modulus, coldflexibility, resistance to crack propagation, thermal degradationresistance, thermal glass transition temperature, melting point,capacity to take a heat set, Z-directional thickness, gauge, specificgravity, density per unit area, weight per unit area, surface area,continuity of surface, dimensional stability, resistance to compressionset, deformability, creep resistance, bonding capacity, adhesivecompatibility, electrical conductance, light transmittance, fluidtransfer capability, washability, resistance to shrinkage, resistance tosolvents, colorability, colorfastness, resistance to UV lightdegradation, microbial resistance, moisture permeability, modulus ofelasticity, abrasion resistance, resilience, durability, strength,tensile strength, hardness, flex elongation, tear strength, and thermalinsulative capacity.

Feature 63. The component of any of features 28 through 62, wherein adensity of at least one of the first plurality of fibers, the secondplurality of fibers, and the entangled first and second pluralities offibers is at least 10% greater in a first section of the component ascompared to a second section of the component, each of the first andsecond sections having a surface area of at least 0.25 cm².

Feature 64. A method of forming a component, the method comprising:placing a first fiber layer adjacent a first carrier screen, the firstfiber layer comprising a first plurality of fibers; placing a scrimadjacent the first fiber layer, the scrim having first surface and anopposite second surface, the scrim first surface being adjacent andoverlapping the first fiber layer in a first Z-directional placement;placing a second fiber layer on the second surface of the scrim, thesecond fiber layer comprising a second plurality of fibers and having afirst surface and an opposite second surface, the first surface of thesecond fiber layer being adjacent and overlapping the second surface ofthe scrim in a second Z-directional placement; and entangling at least aportion of the first plurality of fibers with at least a portion of thesecond plurality of fibers.

Feature 65. The method of feature 64, wherein the component is one of acomponent of an article of footwear, an apparel component, or a sportingequipment component.

Feature 66. The method of any of features 64 and 65, wherein thecomponent is a component of an article of footwear.

Feature 67. The method of any of features 64 through 66, wherein thecomponent is an upper of the article of footwear.

Feature 68. The method of feature 67, wherein the upper of the articleof footwear is comprised of a medial portion, a lateral portion, and aforefoot region of the article of footwear.

Feature 69. The method of any of features 64 through 68, wherein theentangling is performed, at least in part, with a fluid stream.

Feature 70. The method of any of features 64 through 69, wherein thefirst plurality of fibers comprises, at least in part, a plurality ofloose fibers.

Feature 71. The method of any of features 64 through 69, wherein thefirst plurality of fibers comprises, at least in part, a plurality ofshaped fiber pieces.

Feature 72. The method of any of features 64 through 69, wherein thefirst plurality of fibers, at least in part, is adhered to a fugitivebacking.

Feature 73. The method of any of features 64 through 72, furthercomprising placing a second carrier screen adjacent the second surfaceof the second fiber layer;

Feature 74. The method of any of features 64 through 73, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh comprised, at least in part, of a monofilamentpolymeric yarn, fiberglass filament, plastic fiber polyester fiber, apolymer extrusion, a film, cut netting, woven aluminum, woven bronze, ora multiple-material woven composition.

Feature 75. The method of any of features 64 through 74, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including one or more warp apertures and one or morefill apertures.

Feature 76. The method of any of features 64 through 75, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including a plurality of warp apertures and a pluralityof fill apertures, wherein a quantity of warp apertures is between 14and 20, and wherein a quantity of fill apertures is between 14 and 30.

Feature 77. The method of any of features 64 through 75, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including a plurality of warp apertures and a pluralityof fill apertures, wherein a quantity of warp apertures is between 16and 20, and wherein a quantity of fill apertures is between 16 and 20.

Feature 78. The method of any of features 75 through 77, wherein themesh comprises a diameter of 0.005 mm to 0.03 mm

Feature 79. The method of any of features 75 and 77, wherein the meshcomprises a diameter of 0.01 mm to 0.025 mm

Feature 80. The method of any of features 75 through 77, wherein themesh comprises a diameter of 0.01 mm to 0.02 mm

Feature 81. The method of any of features 64 through 80, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises, at least in part, at least one selected frompolyurethanes, thermoplastic polyurethanes, polyesters, polyethers,polyamides, polyolefins, polycarbonates, polyacrylates, aramids,cellulosic materials, glass, carbon, metals, minerals, co-polymersthereof, and any combinations thereof.

Feature 82. The method of any of features 64 through 81, furthercomprising applying energy to the component subsequent to entangling.

Feature 83. The method of any of features 64 through 82, furthercomprising impregnating the component with a polymer and forming thecomponent into a synthetic leather.

Feature 84. The method of any of features 64 through 83, wherein thefirst plurality of fibers comprises a protein-based material.

Feature 85. The method of any of features 64 through 83, wherein thefirst plurality of fibers comprises an animal-derived material and apolymer material.

Feature 86. The method of any of features 64 through 85, wherein thescrim is formed as a knit, woven, braided, non-woven,direct-fiber-placed, molded, cast, extruded, deposited, expanded,reductions-formed, 3D-printed, sheet, film, or embroidered element.

Feature 87. The method of any of features 64 through 86, wherein thecomponent has a first functional zone and a different second functionalzone, the first functional zone having a functional characteristic thatdiffers from the same functional characteristic of the second functionalzone.

Feature 88. The method of feature 87, wherein functional characteristicdiffers by at least 10% between the first and second functional zones.

Feature 89. The method of any of features 87 and 88, wherein thefunctional characteristic is one of air permeability, porosity, moisturewicking capacity, water resistance, water proofing, imperviousness,hydrophobicity, fineness, burst strength, toughness, sheer forceresistance, recovery after elongation, bending modulus, coldflexibility, resistance to crack propagation, thermal degradationresistance, thermal glass transition temperature, melting point,capacity to take a heat set, Z-directional thickness, gauge, specificgravity, density per unit area, weight per unit area, surface area,continuity of surface, dimensional stability, resistance to compressionset, deformability, creep resistance, bonding capacity, adhesivecompatibility, electrical conductance, light transmittance, fluidtransfer capability, washability, resistance to shrinkage, resistance tosolvents, colorability, colorfastness, resistance to UV lightdegradation, microbial resistance, moisture permeability, modulus ofelasticity, abrasion resistance, resilience, durability, strength,tensile strength, hardness, flex elongation, tear strength, and thermalinsulative capacity.

Feature 90. A component formed utilizing the method of any of feature 64through 89.

Feature 91. A component comprising: a first fiber layer comprising afirst plurality of fibers; a scrim including a first surface and anopposite second surface, wherein the scrim first surface is adjacent andoverlapping the first fiber layer in a first Z-directional placement;and a second fiber layer, the second fiber layer comprising a secondplurality of fibers and having a first surface and an opposite secondsurface, the first surface of the second fiber layer being adjacent andoverlapping the second surface of the scrim in a second Z-directionalplacement, wherein at least a portion of the first plurality of fibersis entangled with at least a portion of the second plurality of fibersutilizing at least one carrier screen.

Feature 92. The component of feature 91, wherein the component is one ofa component of an article of footwear, an apparel component, or asporting equipment component.

Feature 93. The component of any of features 91 and 92, wherein thecomponent is a component of an article of footwear.

Feature 94. The component of any of features 91 through 93, wherein thecomponent is an upper of the article of footwear.

Feature 95. The component of any of feature 94, wherein the upper of thearticle of footwear is comprised of a medial portion, a lateral portion,and a forefoot region of the article of footwear.

Feature 96. The component of any of features 91 through 95, wherein thefirst plurality of fibers comprises, at least in part, a plurality ofloose fibers.

Feature 97. The component of any of features 91 through 95, wherein thefirst plurality of fibers comprises, at least in part, a plurality ofshaped fiber pieces.

Feature 98. The component of any of features 91 through 95, wherein thefirst plurality of fibers, at least in part, is adhered to a fugitivebacking.

Feature 99. The component of any of features 91 through 98, wherein theat least one carrier screen is formed of a mesh comprised, at least inpart, of a monofilament polymeric yarn, fiberglass filament, plasticfiber polyester fiber, a polymer extrusion, a film, cut netting, wovenaluminum, woven bronze, or a multiple-material woven composition.

Feature 100. The component of any of features 91 through 99, wherein theat least one carrier screen is formed of a mesh including one or morewarp apertures and one or more fill apertures.

Feature 101. The component of any of features 91 through 100, whereinthe at least one carrier screen is formed of a mesh including aplurality of warp apertures and a plurality of fill apertures, wherein aquantity of warp apertures is between 14 and 20, and wherein a quantityof fill apertures is between 14 and 30.

Feature 102. The component of any of features 91 through 100, whereinthe at least one carrier screen is formed of a mesh including aplurality of warp apertures and a plurality of fill apertures, wherein aquantity of warp apertures is between 16 and 20, and wherein a quantityof fill apertures is between 16 and 20.

Feature 103. The component of any of features 99 through 102, whereinthe mesh comprises a diameter of 0.005 mm to 0.03 mm

Feature 104. The component of any of features 99 and 102, wherein themesh comprises a diameter of 0.01 mm to 0.025 mm

Feature 105. The component of any of features 99 through 102, whereinthe mesh comprises a diameter of 0.01 mm to 0.02 mm

Feature 106. The component of any of features 91 through 105, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises, at least in part, at least one selected frompolyurethanes, thermoplastic polyurethanes, polyesters, polyethers,polyamides, polyolefins, polycarbonates, polyacrylates, aramids,cellulosic materials, glass, carbon, metals, minerals, co-polymersthereof, and any combinations thereof.

Feature 107. The component of any of features 91 through 106, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises a polymeric composition comprised of at least onepolymer.

Feature 108. The component of any of features 91 through 107, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises at least one selected from a thermoplasticpolyurethane, polyurethane, polyester, polyamides, polyolefin,polycarbonate and co-polymers thereof.

Feature 109. The component of any of features 91 through 107, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of at least one polymer that consists essentially ofat least one selected from a thermoplastic polyurethane, polyurethane,polyester, polyamides, polyolefin, polycarbonate and co-polymersthereof.

Feature 110. The component of any of features 91 through 109, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a staple fiber or a continuous filament fiber.

Feature 111. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a linear mass density measurementof 1 denier per filament (dpf) to 9 dpf.

Feature 112. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a linear mass density measurementof 1 denier per filament (dpf) to 4 dpf.

Feature 113. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a linear mass density measurementof 0.001 denier per filament (dpf) to 0.999 dpf.

Feature 114. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a width measurement of 200 micronsto 100 nanometers.

Feature 115. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a width measurement of 100 micronsto 100 nanometers.

Feature 116. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a width measurement of 25 micronsto 0.01 microns.

Feature 117. The component of any of features 91 through 110, wherein atleast one of the first plurality of fibers and the second plurality offibers is comprised of a fiber having a width measurement of 10 micronsto 0.01 microns.

Feature 118. The component of any of features 91 through 117, wherein atleast one of the first fiber layer and the second fiber layer comprisesis a non-woven textile.

Feature 119. The component of any of features 91 through 118, whereinthe component is impregnated forming a synthetic leather.

Feature 120. The component of any of features 91 through 119, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises a protein-based material.

Feature 121. The component of any of features 91 through 120, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises an animal-derived material and a polymer material.

Feature 122. The component of any of features 91 through 121, whereinthe scrim is formed as a knit, woven, braided, non-woven,direct-fiber-placed, molded, cast, extruded, deposited, expanded,reductions-formed, 3D-printed, sheet, film, or embroidered element.

Feature 123. The component of any of features 91 through 122, whereinthe component has a first functional zone and a different secondfunctional zone, the first functional zone having a functionalcharacteristic that differs from the same functional characteristic ofthe second functional zone.

Feature 124. The component of feature 123, wherein functionalcharacteristic differs by at least 10% between the first and secondfunctional zones.

Feature 125. The component of any of features 123 and 124, wherein thefunctional characteristic is one of air permeability, porosity, moisturewicking capacity, water resistance, water proofing, imperviousness,hydrophobicity, fineness, burst strength, toughness, sheer forceresistance, recovery after elongation, bending modulus, coldflexibility, resistance to crack propagation, thermal degradationresistance, thermal glass transition temperature, melting point,capacity to take a heat set, Z-directional thickness, gauge, specificgravity, density per unit area, weight per unit area, surface area,continuity of surface, dimensional stability, resistance to compressionset, deformability, creep resistance, bonding capacity, adhesivecompatibility, electrical conductance, light transmittance, fluidtransfer capability, wash ability, resistance to shrinkage, resistanceto solvents, colorability, colorfastness, resistance to UV lightdegradation, microbial resistance, moisture permeability, modulus ofelasticity, abrasion resistance, resilience, durability, strength,tensile strength, hardness, flex elongation, tear strength, and thermalinsulative capacity.

Feature 126. The component of any of features 91 through 125, wherein adensity of at least one of the first plurality of fibers, the secondplurality of fibers, and the entangled first and second pluralities offibers is at least 10% greater in a first segment of the component ascompared to a second segment of the component, each of the first andsecond segments having a surface area of at least 0.25 cm².

Feature 127. A method of forming a component comprising: placing a firstfiber layer adjacent a first carrier screen, the first fiber layercomprising a first plurality of fibers, wherein the first plurality offibers comprises at least one of a plurality of loose fibers, aplurality of shaped fiber pieces, and a plurality of fibers adhered to afugitive backing; placing a scrim adjacent the first fiber layer, thescrim having first surface and an opposite second surface, the scrimfirst surface being adjacent and overlapping the first fiber layer in afirst Z-directional placement; placing a second fiber layer on thesecond surface of the scrim, the second fiber layer comprising a secondplurality of fibers and having a first surface and an opposite secondsurface, the first surface of the second fiber layer being adjacent andoverlapping the second surface of the scrim in a second Z-directionalplacement; placing a second carrier screen adjacent the second surfaceof the second fiber layer; and entangling at least a portion of thefirst plurality of fibers with at least a portion of the secondplurality of fibers.

Feature 128. The method of feature 127, wherein the component is one ofa component of an article of footwear, an apparel component, or asporting equipment component.

Feature 129. The method of any of features 127 and 128, wherein thecomponent is a component of an article of footwear.

Feature 130. The method of any of features 127 through 129, wherein thecomponent is an upper of the article of footwear.

Feature 131. The method of feature 130, wherein the upper of the articleof footwear is comprised of a medial portion, a lateral portion, and aforefoot region of the article of footwear.

Feature 132. The method of any of features 127 through 131, wherein theentangling is performed, at least in part, with a fluid stream.

Feature 133. The method of any of features 127 through 132, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises, at least in part, a plurality of loose fibers.

Feature 134. The method of any of features 127 through 132, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises, at least in part, a plurality of shaped fiber pieces.

Feature 135. The method of any of features 127 through 132, wherein atleast one of the first plurality of fibers and the second plurality offibers, at least in part, is adhered to a fugitive backing.

Feature 136. The method of any of features 127 through 135, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh comprised, at least in part, of a monofilamentpolymeric yarn, fiberglass filament, plastic fiber polyester fiber, apolymer extrusion, a film, cut netting, woven aluminum, woven bronze, ora multiple-material woven composition.

Feature 137. The method of any of features 127 through 136, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including one or more warp apertures and one or morefill apertures.

Feature 138. The method of any of features 127 through 137, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including a plurality of warp apertures and a pluralityof fill apertures, wherein a quantity of warp apertures is between 14and 20, and wherein a quantity of fill apertures is between 14 and 30.

Feature 139. The method of any of features 127 through 137, wherein atleast one of the first carrier screen and the second carrier screen isformed of a mesh including a plurality of warp apertures and a pluralityof fill apertures, wherein a quantity of warp apertures is between 16and 20, and wherein a quantity of fill apertures is between 16 and 20.

Feature 140. The method of any of features 136 through 139, wherein themesh comprises a diameter of 0.005 mm to 0.03 mm

Feature 141. The method of any of features 136 and 139, wherein the meshcomprises a diameter of 0.01 mm to 0.025 mm

Feature 142. The method of any of features 136 through 139, wherein themesh comprises a diameter of 0.01 mm to 0.02 mm

Feature 143. The method of any of features 127 through 142, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises, at least in part, one selected from an aramid, aglass, a cellulose-based material, a protein-based material, athermoplastic polyurethane, polyurethane, polyester, polyamides,polyolefin, or polycarbonate.

Feature 144. The method of any of features 127 through 143, furthercomprising applying energy to the component subsequent to entangling.

Feature 145. The method of any of features 127 through 144, furthercomprising impregnating the component with a polymer and forming thecomponent into a synthetic leather.

Feature 146. The method of any of features 127 through 145, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises a protein-based material.

Feature 147. The method of any of features 127 through 146, wherein atleast one of the first plurality of fibers and the second plurality offibers comprises an animal-derived material and a polymer material.

Feature 148. The method of any of features 127 through 147, wherein thescrim is formed as a knit, woven, braided, non-woven,direct-fiber-placed, molded, cast, extruded, deposited, expanded,reductions-formed, sheet, film, or embroidered element.

Feature 149. The method of any of features 127 through 148, wherein thecomponent has a first functional zone and a different second functionalzone, the first functional zone having a functional characteristic thatdiffers from the same functional characteristic of the second functionalzone.

Feature 150. The method of feature 149, wherein the functionalcharacteristic differs by at least 10% between the first and secondfunctional zones.

Feature 151. The method of any of features 149 and 150, wherein thefunctional characteristic is one of air permeability, porosity, moisturewicking capacity, water resistance, water proofing, imperviousness,hydrophobicity, fineness, burst strength, toughness, sheer forceresistance, recovery after elongation, bending modulus, coldflexibility, resistance to crack propagation, thermal degradationresistance, thermal glass transition temperature, melting point,capacity to take a heat set, Z-directional thickness, gauge, specificgravity, density per unit area, weight per unit area, surface area,continuity of surface, dimensional stability, resistance to compressionset, deformability, creep resistance, bonding capacity, adhesivecompatibility, electrical conductance, light transmittance, fluidtransfer capability, wash ability, resistance to shrinkage, resistanceto solvents, colorability, colorfastness, resistance to UV lightdegradation, microbial resistance, moisture permeability, modulus ofelasticity, abrasion resistance, resilience, durability, strength,tensile strength, hardness, flex elongation, tear strength, and thermalinsulative capacity.

Feature 152. A component formed utilizing the method of any of features127 through 151.

What is claimed is:
 1. A method of forming a component, the methodcomprising: placing a fiber layer adjacent a first carrier screen, thefiber layer comprising a first plurality of fibers; placing a scrim onthe first fiber layer, wherein the scrim comprises a second plurality offibers, wherein the scrim includes a first surface and an oppositesecond surface, and wherein the scrim first surface is adjacent andoverlapping the first fiber layer in a Z-directional placement; andentangling at least a portion of the first plurality of fibers with atleast a portion of the second plurality of fibers.
 2. The method ofclaim 1, wherein the component is one of a component of an article offootwear, an apparel component, or a sporting equipment component. 3.The method of claim 1, wherein the entangling is performed, at least inpart, with a fluid stream.
 4. The method of claim 1, wherein the firstplurality of fibers comprises, at least in part, at least one of aplurality of loose fibers and a plurality of shaped fiber pieces.
 5. Themethod of claim 1, wherein the first plurality of fibers, at least inpart, is adhered to a fugitive backing.
 6. The method of claim 1,further comprising placing a second carrier screen adjacent at least aportion of the second surface of the scrim.
 7. The method of claim 6,wherein at least one of the first carrier screen and the second carrierscreen is formed of a mesh comprised, at least in part, a monofilamentpolymeric yarn, fiberglass filament, plastic fiber polyester fiber, apolymer extrusion, a film, cut netting, woven aluminum, woven bronze, ora multiple-material woven composition.
 8. The method of claim 6, whereinat least one of the first carrier screen and the second carrier screenis formed of a mesh including a plurality of warp apertures and aplurality of fill apertures, wherein a quantity of warp apertures isbetween 14 and 20, and wherein a quantity of fill apertures is between14 and
 30. 9. The method of claim 6, wherein at least one of the firstcarrier screen and the second carrier screen is formed of a meshincluding a plurality of warp apertures and a plurality of fillapertures, wherein a quantity of warp apertures is between 16 and 20,and wherein a quantity of fill apertures is between 16 and
 20. 10. Themethod of claim 1, further comprising: placing a second fiber layeradjacent at least a portion of the second surface of the scrim, thesecond fiber layer comprising a third plurality of fibers and having afirst surface and an opposite second surface, the first surface of thesecond fiber layer being adjacent and overlapping at least the portionof the second surface of the scrim in a second Z-directional placement;and entangling at least a portion of the third plurality of fibers withat least a portion of the second plurality of fibers.
 11. The method ofclaim 1, further comprising placing a second carrier screen adjacent atleast a portion of the second surface of the second fiber layer.
 12. Themethod of claim 1, wherein the component has a first functional zone anda second functional zone, wherein the first and second functional zonesinclude a functional characteristic that differs by at least 10% betweenthe first and second functional zones, and wherein the functionalcharacteristic is one of air permeability, porosity, moisture wickingcapacity, water resistance, water proofing, imperviousness,hydrophobicity, fineness, burst strength, toughness, sheer forceresistance, recovery after elongation, bending modulus, coldflexibility, resistance to crack propagation, thermal degradationresistance, thermal glass transition temperature, melting point,capacity to take a heat set, Z-directional thickness, gauge, specificgravity, density per unit area, weight per unit area, surface area,continuity of surface, dimensional stability, resistance to compressionset, deformability, creep resistance, bonding capacity, adhesivecompatibility, electrical conductance, light transmittance, fluidtransfer capability, wash ability, resistance to shrinkage, resistanceto solvents, colorability, colorfastness, resistance to UV lightdegradation, microbial resistance, moisture permeability, modulus ofelasticity, abrasion resistance, resilience, durability, strength,tensile strength, hardness, flex elongation, tear strength, and thermalinsulative capacity.
 13. A method of forming a component, the methodcomprising: placing a first fiber layer adjacent a first carrier screen,the first fiber layer comprising a first plurality of fibers; placing ascrim adjacent the first fiber layer, the scrim having a first surfaceand an opposite second surface, the scrim first surface being adjacentand overlapping the first fiber layer in a first Z-directionalplacement; placing a second fiber layer on the second surface of thescrim, the second fiber layer comprising a second plurality of fibersand having a first surface and an opposite second surface, the firstsurface of the second fiber layer being adjacent and overlapping thesecond surface of the scrim in a second Z-directional placement; andentangling at least a portion of the first plurality of fibers with atleast a portion of the second plurality of fibers.
 14. The method ofclaim 13, wherein the entangling is performed, at least in part, with afluid stream.
 15. The method of claim 13, wherein the first plurality offibers comprises at least one of a plurality of loose fibers and aplurality of shaped fiber pieces.
 16. The method of claim 13, whereinthe first plurality of fibers is adhered to a fugitive backing.
 17. Themethod of claim 13, further comprising placing a second carrier screenadjacent the second surface of the second fiber layer.
 18. The method ofclaim 17, wherein at least one of the first carrier screen and thesecond carrier screen is formed of a mesh comprised, at least in part, amonofilament polymeric yarn, fiberglass filament, plastic fiberpolyester fiber, a polymer extrusion, a film, cut netting, wovenaluminum, woven bronze, or a multiple-material woven composition. 19.The method of claim 17, wherein at least one of the first carrier screenand the second carrier screen is formed of a mesh including a pluralityof warp apertures and a plurality of fill apertures, wherein a quantityof warp apertures is between 14 and 20, and wherein a quantity of fillapertures is between 14 and
 30. 20. A method of forming a component, themethod comprising: placing a first fiber layer adjacent a first carrierscreen, the first fiber layer comprising a first plurality of fibers,wherein the first plurality of fibers comprises at least one of aplurality of loose fibers, a plurality of shaped fiber pieces, and aplurality of fibers adhered to a fugitive backing; placing a scrimadjacent the first fiber layer, the scrim having first surface and anopposite second surface, the scrim first surface being adjacent andoverlapping the first fiber layer in a first Z-directional placement;placing a second fiber layer on the second surface of the scrim, thesecond fiber layer comprising a second plurality of fibers and having afirst surface and an opposite second surface, the first surface of thesecond fiber layer being adjacent and overlapping the second surface ofthe scrim in a second Z-directional placement; placing a second carrierscreen adjacent the second surface of the second fiber layer; andentangling at least a portion of the first plurality of fibers with atleast a portion of the second plurality of fibers.